Hydrocarbonaceous Material Processing Methods and Apparatus

ABSTRACT

Methods and apparatus are disclosed for possibly producing pipeline-ready heavy oil from substantially non-pumpable oil feeds. The methods and apparatus may be designed to produce such pipeline-ready heavy oils in the production field. Such methods and apparatus may involve thermal soaking of liquid hydrocarbonaceous inputs in thermal environments ( 2 ) to generate, though chemical reaction, an increased distillate amount as compared with conventional boiling technologies.

CROSS-REFERENCES TO RELATED APPLICATION

This is an international application claiming priority to each: U.S.Provisional Application 60/633,744, filed 6 Dec. 2004, and entitled“Distillate Recovery Methods and Apparatus for Oil ProcessingApplications”; and U.S. Provisional Application 60/633,856, filed 6 Dec.2004, and entitled “Methods and Apparatus for Producing Heavy Oil FromExtra-Heavy Feed Oils”, each provisional application incorporated hereinby reference.

ACKNOWLEDGMENT OF GOVERNMENT SUPPORT

This invention was made with federal government support underCooperative Agreement No. USDOE contract DE-FC26-98FT40323 awarded bythe United States Department of Energy. The federal government may havecertain rights in this invention.

TECHNICAL FIELD

Generally, this inventive technology relates to oil processing methodsand apparatus. More specifically, specific aspects of the technologyrelate to the use of thermal environments, perhaps each as part of astage in a multi-stage processing apparatus and perhaps each adapted tocontinuously process an oil input (including a hydrocarbonaceous bottomsoutput by an upstream stage). Such oil input may be heated for aresidence time and at a specific temperature. Such may increase theamount of vapors emitted as compared with conventional processingtechnologies, in addition to affording enhanced control over oilprocessing operations by providing a highly tunable system.

BACKGROUND

It is well known that oil is a critical commodity for modern societies.To meet this need, oil production is engaged in on a worldwide basisunder a variety of conditions and using a variety of techniques.Petroleum reserves (e.g., extra heavy oil and bitumen) that were oncepassed over in favor of easier to extract reserves are now receivingconsiderably more attention than in the past, and in fact are the targetof many extraction efforts in Canada and elsewhere. Indeed, thecontinued development of oil production techniques to increase theeconomic efficiency of oil production may be a constant goal of the oilproduction industry.

As is well known, crude oil and partially refined oil often may consistof two or more physical and/or chemical components or constituents. Inmany oil production applications, it may be desirable to process an oilso as to separate out such various physical and/or chemicalconstituents. Such separation may be desirable to recover oil componentswith separate uses that may have independent commercial value and/or toproduce an oil at a well site that can be pumped for further processingelsewhere.

A key aspect of conventional oil production practices may betransporting oil by pumping it through pipelines. However, extra-heavyoils may not be able to be pumped in existing pipelines in their naturalstate due to their high densities and kinematic viscosities. Rather,these oils usually must be processed into pipeline-ready heavy oils.Pipeline-ready heavy oils may be defined as those having, at pipelinetemperatures, densities above 19 degrees API and kinematic viscositiesbelow 350 centistokes. Conventional techniques for processingextra-heavy oils into pipeline-ready heavy oils typically involvemixture with either natural gas condensate or lighter hydrocarbons toproduce a blended oil that can be pumped. However, using the methods andapparatus of this disclosure, the need for a diluent to produce ablended oil may be eliminated and a directly pumpable oil may beproduced instead.

DISCLOSURE OF INVENTION

Methods and apparatus are disclosed for possibly producingpipeline-ready heavy oil from substantially non-pumpable oil feeds. Themethods and apparatus may be designed to produce such pipeline-readyheavy oils in the production field. Such methods and apparatus mayinvolve thermal soaking of liquid hydrocabonaceous inputs to generate,though chemical reaction, an increased distillate amount as comparedwith conventional boiling technologies.

Accordingly, an object of the inventive technology may be the separationvia physical and/or chemical processes of physical and/or chemicalconstituents of an oil.

Another object of the inventive technology may be to accomplish suchseparation using methods and apparatus involving thermal environment(s)in which an oil may be heated to a certain temperature for a residencetime.

Still another object of the inventive technology may be a novel methodof generating a pumpable oil (e.g., heavy oil) from a substantiallynon-pumpable oil (e.g., extra heavy oil or bitumen).

Another object of the inventive technology may be to increase vaporyields as compared with conventional oil processing technologies.

A further object of the inventive technology may be to provide suchdistillate recovery in conjunction with the use of methods and apparatusfor producing heavy oil from non-pumpable oil feeds.

Yet another object of the inventive technology may be to provide a feedto a continuous coker.

Naturally, further objects of the inventive technology are disclosedthroughout other areas of the specification, and claims when presented.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block flow diagram showing a process for producingpipeline-ready heavy oil from extra-heavy feed oils.

FIG. 2 is a graph showing the results of operation of one embodiment ofan inventive unit at short residence times for certain embodiments ofthe inventive technology.

FIG. 3 is a graph showing the results of operation of one embodiment ofan inventive unit at medium residence times for certain embodiments ofthe inventive technology.

FIG. 4 is a graph showing the specific gravity of overhead distillateproduced by a unit operating at medium residence times for certainembodiments of the inventive technology.

FIG. 5 is a graph showing differential mass balances by boiling pointfraction produced by a unit for certain embodiments of the inventivetechnology.

FIG. 6 is a graph showing the yield of overhead at various temperaturesand residence times produced by a unit for certain embodiments of theinventive technology.

FIG. 7 is a graph showing density variations produced by a unit forcertain embodiments of the inventive technology.

FIG. 8 shows one multistage embodiment of the inventive technology, withone vessel and weir defining two thermal environments, and with oneseparate condenser for both thermal environments.

FIG. 9 shows one multistage embodiment of the inventive technology, withone vessel and weir forming two thermal environments, and with oneseparate condenser for each thermal environment.

FIG. 10 shows one multistage embodiment of the inventive technology,with one vessel defining each thermal environment, and with one separatecondenser corresponding to both thermal environments.

FIG. 11 shows one multistage embodiment of the inventive technology,with one vessel defining each of two thermal environments, and with oneseparate condenser for each thermal environment.

FIG. 12 shows one multistage embodiment of the inventive technology,with one vessel and weir defining two thermal environments, and with oneintegral condenser.

FIG. 13 shows one multistage embodiment of the inventive technology,with one vessel and weir defining two thermal environments, and with twointegral condensers.

FIG. 14 shows one multistage embodiment of the inventive technology,with one vessel defining each of two thermal environments, and with oneintegral condenser corresponding to each thermal environment.

FIG. 15 shows a schematic representation of one embodiment of aninventive method to generate a pumpable oil from a substantiallynon-pumpable oil.

MODES FOR CARRYING OUT THE INVENTION

The present inventive technology includes a variety of aspects, whichmay be combined in different ways. The following descriptions areprovided to list elements and describe some of the embodiments of thepresent inventive technology. These elements are listed with initialembodiments, however it should be understood that they may be combinedin any manner and in any number to create additional embodiments. Thevariously described examples and preferred embodiments should not beconstrued to limit the present inventive technology to only theexplicitly described systems, techniques, and applications. Further,this description should be understood to support and encompassdescriptions and claims of all the various embodiments, systems,techniques, methods, devices, and applications with any number of thedisclosed elements, with each element alone, and also with any and allvarious permutations and combinations of all elements in this or anysubsequent application.

Certain preferred embodiments of the inventive technology involve theprocessing of liquid hydrocarbonaceous material (more commonly referredto as oil). Specific embodiments may focus on the reduction of theviscosity of a feed oil so as to render it more amenable to pumping.Methods and apparatus are disclosed that in some embodiments of theinventive technology may produce pipeline-ready heavy oil fromextra-heavy feed oils or bitumens. Indeed, some embodiments may inputsuch substantially non-pumpable oil (e.g., one with a viscosity that isabove a viscosity specification as specified by governing “code”) andprocess it so as to yield a hydrocarbonaceous material with a loweredviscosity. Such non-pumpable oil may be a crude oil feedstock (e.g.,extra heavy oil or bitumen), and processes to reduce viscosity may takeplace in the field, at a crude extraction site (e.g., a production sitesuch as a well site). The process feed may be bitumen, or extra-heavyoil such as that which may be obtained when using steam-assistedtechnologies to produce non-upgraded bitumen from Canadian oil sandsdeposits or when producing extra-heavy oils such as those found in theOrinoco Belt in Venezuela.

In certain embodiments whose goal is to produce a pipeline ready oil, itmay be affirmatively assured that a viscosity of an oil substantiallymatches that viscosity specified for pumpable oil (e.g., a maximumviscosity of an oil for it to be transported via pumping through pipes).Such may involve preparing a condensate having such a matchingviscosity, or, perhaps preparing a condensate that has a viscosity thatis less than such specified pumping oil viscosity and adding thatcondensate to an excessively viscous oil (e.g., a crude) so as to yielda pumpable oil (e.g., one having a substantially matching viscosity).Such pumpable oil may be referred to as pipeline ready, and may be oftenreferred to as merely a heavy oil. Associated methods and apparatus maybe designed to produce such pipeline-ready heavy oil in the productionfield and may eliminate the need for separately prepared condensate orlight hydrocarbon diluents that are now typically used to make pumpableblends from ultra-heavy feedstocks.

One inventive aspect of certain embodiments of the technology hereindescribed may relate to continual processing during operation. Indeed,certain embodiments may involve continuous input elements (e.g., a pump,pipe and an orifice) that continually input a hydrocarbonaceousmaterial—as opposed to merely having batch mode operative capabilities.Such, of course, may improve efficiency of the overall process, perhapsreducing labor, power and heating costs as well.

Thermal environments (2) in which a liquid hydrocarbonaceous materialmay be held and heated for a residence time may be found (perhaps inserial arrangements) in particular embodiments. In such arrangements,the output of one thermal environment (e.g., bottoms) may serve as theinput to the “next” thermal environment (e.g., that thermal environmentthat is immediately downflow). Thermal environment is intended as abroad term, and includes not only a vessel, but also any structure inwhich a liquid hydrocarbonaceous material can be held and heated. Assuch, one vessel may define two thermal environments, as where there isa weir (5) of sorts (a type of physical segregator) in that singlevessel (see FIGS. 8, 9, 12 and 13). Such a weir may enable differentialprocessing (e.g., heating to different temperatures and perhaps fordifferent times) of oil held in segregated portions of the vessel. Ofcourse, in keeping with the broad definition of oil (a liquidhydrocarbonaceous material), the liquid hydrocarbonaceous bottoms from athermal environment is a type of oil.

Additionally, it should be noted that a thermal environment has avolumetric capacity (thereby enabling the holding of contents for aresidence time so that they can be heated for that time). Of course,this capacity—the maximum amount of liquid hydrocarbonaceous materialsthat can be held and heated therein—need not be used in its entiretyduring processing (although, e.g., a vessel may indeed be filled tocapacity during operation). Indeed, in coordinating aspects of thesystem such that a specific thermal environment holds an oil for acertain time as desired (a residence time), it may only be necessary toassure that, given a certain input rate of the liquid hydrocarbonaceousmaterial and output rate of a portion of that material, the volumetriccapacity not too small (e.g., the vessel is large enough given thesespecific constraints). As should be understood, aspects that may becoordinated so as to result in a desired residence time may includeinput rate, output rate, temperature of the thermal environment(s), andeven pressure within the thermal environment (lower pressures mayenhance volatility of constituents, e.g.). Indeed, given a certaintemperature and residence time, too low an output rate may result in anincrease in the volume of the oil in that thermal environment, and aneventual, undesired “overflow”. Certainly it is also clear that theoutput rate of a thermal environment (referring to the non-gaseous andnon-vaporous outputs) is typically lower than the input rate because ofthe hydrocarbonaceous materials that are vaporized or emitted as gas. Itshould also be noted that pressures of the thermal environments may varyto yield vaporous products as desired—pressures may be vacuum,atmospheric, or above atmospheric (including but not limited to slightlyabove atmospheric, such as substantially at 1%, 3%, 5%, 7%, 10%, 12% and15%). Thermal environment temperatures can be low boiling pointtemperatures (e.g., less than 40° F., less than 70° F., less than 100°F., less than 150° F., less than 200° F., less than 250° F., less than300° F., less than 370° F., less than 400° F., less than 450° F., lessthan 500° F., less than 550° F., less than 600° F., less than 650° F.,less than 700° F., less than 710° F.).

That aspects of the inventive technology are able to yield greaterprocessed hydrocarbons (e.g., those hydrocarbonaceous materials that arevaporized and subsequently condensed) than observed when conventionalprocessing methods are used may be attributable to residence time.Essentially, the thermal soaking that takes place during the prolongedheating of the hydrocarbonaceous contents of the thermal environment(s)cracks constituent hydrocarbonaceous materials, thereby producingadditional amounts of lighter hydrocarbonaceous materials that may thenbe vaporized. The chemical reaction may yield hydrocarbonaceousmaterials that, upon their appearance as a vapor, may have acondensation point that is less than or equal to the temperature towhich the contents of the thermal environment are heated (which may beat least a hydrocarbonaceous material constituent boiling pointtemperature). Further, the molecules cracked may even be heavier thanthe heaviest molecules evaporated. Residence times may be selected basedon data relative to the vaporous response at different residence timesat a certain (or perhaps changing) temperature. Such data, whether inthe form of graphs, charts, tables or in other form, may also be usefulin coordinating aspects of the inventive apparatus and methods to yieldproducts as intended. It should be noted that at some point, theadditional yields due to cracking and subsequent vaporization diminishand there is little economic sense in holding and continuing to heat theoil at that temperature. Then, of course, it may be prudent to outputthe held oil to the next thermal environment (perhaps with a highertemperature to remove heavier hydrocarbons), or, perhaps to a coker (3).

Residence times for each thermal environment may be different, or indeedthey may be similar to all or only some of other thermal environmentsthat may exist. Residence times may be those residence times that resultin a vapor yield as desired (which of course includes not onlyvaporization of hydrocarbonaceous material constituents, but also ofthose hydrocarbonaceous materials that are generated through cracking).An ideal residence time for a certain thermal environment may be lessthan that residence time which, at its completion (e.g., at the end ofeight hours) does not crack hydrocarbonaceous molecules. However, theremay be some time before the observance of absolutely no (or de minimus)cracking at which the “residential holding” should be terminated, foreconomic reasons. Of course, heating during the residence time iscostly, and such costs will not be justified by the reduced vaporousreturns, at some point in time. That point may vary, of course, perhapsdepending on the hydrocarbonaceous material constituent (pentane, water,ethane, etc.) that a thermal environment intends to remove. Possibleresidence times include, but are not limited to: five minutes, fifteenminutes, one-half hour, one hour, two hours, three hours, four hours,five hours, six hours, seven hours, eight hours, nine hours, and tenhours.

It should be noted also there is, of course, a limit to the number ofstages (each with an inlet and outlet, heat source (1) and its uniquethermal environment) that are to be employed in a distillate recoveryunit (7) perhaps referred to hereinafter as merely “unit”). Merely oneof many different embodiments of such a unit is as Depending on perhapsthe target viscosity (which may itself depend on the pumpable oilviscosity specification, the viscosity of the incoming crude, andwhether a processed condensate yield is to be added to a substantiallynon-pumpable input crude, or instead pumped itself), the number ofstages may vary (from perhaps one to twenty). However, other goals ofthe unit—and perhaps the coker also—including merely the preparation ofa desired processed hydrocarbon, may govern the number of stages. Insuch manner, and given the overriding nature of economics in petroleumprocessing, such decisions may be made to result in desired processingeconomics. It will be noted, perhaps tangentially, that in keeping withthe broad meaning that the term “distillate recovery unit” has assumedas used by the inventors, the term distillate recovery unit may applyeven to those apparatus that do not effect recovery of a distillate (butperhaps instead merely effect recovery of a vapor that is subsequentlycondensed in a separate apparatus).

As is well known, a heat source can relate to any of a variety ofmanners in which a mass may be heated, including but not limited tonatural gas, electrical, use of gas yielded during methane processing,burning of solid fuel, etc. Of course, the heat source may be adjustableso as to heat the oil in the thermal environments as desired. One heatsource may heat more than one thermal environment, or one or more (orall) thermal environments may have its own heat source.

Certain embodiments of the inventive technology may include a vapor andgas collection system (which, in part or entirety, may be referenced as(6)). Indeed, whenever a condenser (4) acts on vapors, they are deemedto have been collected (thus, whenever the apparatus includes acondenser, it must include a vapor and gas collection system, even wherethat apparatus forms a part of the condenser, is one in the same withthe condenser, or is separate from the condenser). Such apparatus arewell known in the art, and include but are not limited to sweep gassystems (e.g., including those that use methane as a sweep gas) and thatpart of distilling trays or bubble caps (and perhaps other structuralparts, such as any upper “ceiling” of the thermal environment(s) thatmay exist) that act to establish vapors such that they can be condensed.That sweep gas may be later removed from the collected gases and vapors,as is also well known in the art. Upper inlets are part of the vapor andgas collection system (which may further include, in at least oneembodiment, a pressurized tank (9) of methane, as but one example). Ofcourse, this methane may be recycled from its source as a product ofother sub-processes in the system. As used herein, for purposes ofclarity, the term vapor may refer to condensable mass while gas mayrefer to non-condensable mass. Further, it should be understood that avapor and gas collection system is said to exist as long as vapors arecollected (e.g., even where there are little or no gases collected).

It should be understood that certain embodiments may include acondenser(s). As is well known, temperatures in a condenser may besufficiently low to condense vapor(s) of interest. In keeping with thebroad nature of the inventive technology, a condenser may correspond to(i.e., operate on the vapors of) more than one thermal environment.Indeed, one condenser may correspond to all thermal environments in amultistage distillate recovery unit. However, there may be one condenserfor each thermal environment, or, in a single multistage unit, one ormore thermal environments may have only one corresponding condenser,while one or more of the remaining thermal environments may have two ormore corresponding condensers. Regardless, condensers (and vapor and gascollection system, for that matter) may be established integrally (seeFIGS. 12-14) with the thermal environment with which they correspond(distilling tray(s) or bubble caps near the top thereof, as but twoexamples), or separately therefrom (see FIGS. 8-11).

In some embodiments, an inventive apparatus (which in some embodimentsmay be termed a distillate recovery unit) may heat the incoming bottoms(whether flash or otherwise) in stages, perhaps in some embodiments toremove lighter boiling hydrocarbons and perhaps to produce a bottomsstream that becomes progressively heavier. In certain embodiments,operating conditions in the distillate recovery unit may be varied overwide ranges perhaps to change both the quantity and the quality of thehydrocarbons leaving the system as liquids and vapors. For example,operating at short residence times (perhaps a minute or less) and atmoderate temperatures (perhaps up to 650 or 700 F) may producehydrocarbon vapors that may be characteristic of the normal boilingpoint ranges in the feed oil. Little or no chemical modification of thefeedstock may be achieved and a purely physical separation may occurunder such conditions. The resultant overhead yields from the thermalenvironments may possibly be estimated using the normal boiling pointcurve for the hydrocarbon of interest. However, longer residence timesmay indeed crack hydrocarbonaceous constituents, and yield an increasein the vaporous emissions as compared with those heating processes thatdo not involve a thermal soak.

To illustrate this and related aspects of the inventive technology,particular reference is made to certain figures. FIG. 2 illustrates forone embodiment of the inventive technology the fraction of an incomingCold Lake crude oil that may evaporate and possibly report overhead whenthe temperature of the boiling stage is held at temperatures perhapsvarying between 400 to 750 F. In this instance, residence times in thethermal environments may possibly be less than five minutes, and anuncracked distillate product may be recovered from the overheadcondensers. The quantity of material collected as overhead may agreewith that expected from normal boiling point considerations.

FIG. 3 illustrates for one embodiment of the inventive technology thatif the residence time in the boiling stage is increased from 1-5 minutesto 15-30 minutes, chemical alterations in the material flowing overheadmay begin to occur. Significant departures from normal boiling behaviormay begin to be noticed at thermal environment temperatures, perhapsabove 675 F, and the yields of materials collected overhead may begin toincrease dramatically.

FIG. 4 illustrates for one embodiment of the inventive technology thatthe specific gravity of the distillate product produced by operation atmedium residence times may not appear to vary with thermal environmenttemperature, although the density of the bottoms output from thermalenvironments may appear to do so. As may be expected, the bottoms maybecome heavier as lighter materials are perhaps progressively removed.The possible constancy in overhead product quality may be suggestive ofprogressively greater cleavage of carbon-sulfur bonds as the stilltemperature is raised.

FIGS. 5 and 6 illustrate for one embodiment of the inventive technologythat as residence times may be increased first to an hour and then totwo hours, the improvements in overall overhead yield may continue to berealized. A “trade-off” may exist between residence time andtemperature, however, and maximum yields may only be achieved at longresidence times.

FIG. 7 illustrates for one embodiment of the inventive technology thatthe trends which may have been observed earlier with respect to thespecific gravities of the overhead product and the thermal environmentbottoms may continue as residence times are increased. This may allowconsiderable flexibility in the design and layout of inventive units.

In some embodiments, perhaps depending upon the temperature andresidence time of a thermal stage in the distillate recovery unit, thehydrocarbon liquids and vapors emerging from the stage may be indicativeof perhaps simple boiling at one extreme to perhaps substantial crackingof the heavier hydrocarbons to lighter products at the other. The degreeto which either extreme is utilized in an operating system may be afunction of its design. Full exploitation of the phenomena may enablecustom-designed equipment to be perhaps highly and selectively optimized(tuned) for a given feedstock.

Of course, one of the goals of certain embodiments of the inventivetechnology is to remove from a hydrocarbonaceous material input (e.g.,an unprocessed crude oil) certain constituents thereof. Particularembodiments may focus on the removal of light hydrocarbons (e.g., thosewith relatively low boiling points). However, these and otherembodiments may include a water removal stage that typically wouldappear as the first stage of a multistage processing unit. Such stage(which preferably would include a thermal environment) would heatincoming hydrocarbonaceous material to vaporize liquid water which,although not a hydrocarbaonaceous material, often is a hydrocarbonaceousmaterial constituent—particularly when that material is an unprocessedcrude. Embodiments with such a water evaporization stage may include athermal environment (e.g., having a holding capability), but certainlythere may be other manners in which water may be evaporated from a “wet”crude (e.g., free expansion (see 10), settling tank, non-retentiveheating)—whether within or outside of the unit. In certain embodiments,water may be removed from an incoming oil to generate an anhydrous oil,and subsequently such “dry” oil may be input to the inventive processingunit.

Again, the feed to the process might not need to be free of water (orsolids, for that matter). Indeed it may possibly contain up to 10% wateror 20% BS&W if the water content is below 10%. In those embodimentswhere the input to the processing unit is anhydrous, the water may havebeen removed by a free expansion, or perhaps a settling tank (or simpleheating and vaporization).

When free expansion water removal techniques are used, the feed may befirst pressurized to perhaps as much as 800 psia and then heated totemperatures perhaps as high as 650 F. This hot pressurized stream maythen be expanded to atmospheric pressure using free expansion, possiblythrough a valve (Joule-Thompson expansion), during which the water maybe flashed off, then possibly leaving the system as a benign vapor. Theoptimal combination of pressure and temperature in this sub-process maydepend upon the water content of the incoming feed. It may be that thegreater the water content, the higher the pressure and temperaturerequired to effect its release. The warm, anhydrous flash bottoms thatmay be left after the removal of the water then may be fed to theprocessing unit (with its thermal environments) for further processing.

Certain embodiments may include a coker. Typically, such a coker wouldbe continuous (as opposed to only batch-mode operable), and may involvephysical agitation (due to, perhaps, an auger), a feature that typicallyis not found in thermal environments found in the unit itself. Adescription of a continuous coker that might find application in theoverall apparatus may be found in U.S. Pat. No. 6,972,085, issuing 6Dec. 2005, hereby incorporated herein by reference. For optimaloperation, such continuous coker may include a liquid level control thatallows the coker to maintain a constant liquid level (even when the feedrate changes). Such a control could be achieved, for example, by aproperly sized and situated downcomer.

Certain inventive methods may include the step of generating a condensedcombination of vapors yielded during holding steps. Such generation maytake place with a condensate generation apparatus, that may be: (a) ineither order, a condenser, and a combiner (that combines either vaporsor condensate, as appropriate depending on whether it is up ordownstream of the condenser(s); or (b) a condenser that receivesuncombined vapors (from one or more thermal environments) and combinesthem itself, internally. Explained in terms of corollary method steps,such aforementioned “generating” step may be done either by firstcombining vapors from more than one thermal environment and thencondensing them, or by first condensing vapors in more than onecondenser (e.g., one condenser corresponding to each thermalenvironment) and then combining the condensate, or by using onecondenser acting on vapors that are separate before their input to thecondenser.

Of course, to yield different hydrocarbonaceous constituent condensates,different thermal environments may have different temperatures.Typically, temperatures of thermal environments would increase as thehydrocarbonaceous material travels downstream, encountering differentthermal environments. However, if the intent of the unit is merely tocreate a pumpable (e.g., “on spec”) condensate, then it may not benecessary to remove certain heavier hydrocarbonaceous materialconstituents. Further, given the constraints of a particular processingproblem to be solved, one might only want to yield constituents having acertain “weight” or less (e.g., pentanes and lighter).

Certain embodiments may comprise a condensate admixing apparatus (15)that dilutes a substantially non-pumpable oil to a viscosity that is ator perhaps below a specification viscosity by adding a lower viscositymaterial (e.g., a processed condensate) to an “out of spec” oil (e.g., acrude whose viscosity is greater than a viscosity specification). Suchembodiments may involve a sidestream fraction withdrawal system (11)that may withdrawal from an incoming crude a flow to be processed (or aflow to which a processed, lower viscosity condensate is to be added). Asubstantially non-pumpable oil may be an oil that has a viscosity thatis greater than a pumpable oil viscosity specification (which may be amaximum viscosity). Further, although it may be correct that for aliquid to be properly pumpable indices other than viscosity may need tobe at a specified value or within a specified range, processing anexcessively viscous liquid so that it is pumpable (even where thatprocessing involves only the addition of a diluent prepared from asidestreamed fraction) will involve a decrease in viscosity. Furthersteps, at least some of which are well known in the art, may need to betaken to render an oil that is entirely “on-specification” for pumping.

In some embodiments, the processing unit may heat the incoming bottoms(whether flash or otherwise) in stages (each stage characterizedprimarily by a thermal environment) to possibly remove lighter boilinghydrocarbons and to possibly produce a bottoms stream that becomesprogressively heavier. In various embodiments, operating conditions inthe unit may be varied over wide ranges to perhaps change both thequantity and the quality of the hydrocarbons leaving the system asliquids and vapors. For example (as mentioned above), in one embodiment,operating at short residence times (perhaps a minute or less) and atmoderate temperatures (perhaps up to 650 or 700 F) may producehydrocarbon vapors characteristic of the boiling point ranges in thefeed oil. Little or no chemical modification may occur and a purelyphysical separation may be achieved. In other embodiments, as processingseverity may be increased, more and more chemical alteration of theboiling liquid may occur and the nature of the overhead product maychange. Also, as alluded to above, it may be that the productcomposition from the processing unit may vary with the nature of thefeed and may be altered by changing the operating parameters of thesystem. The bottoms from the unit may be referred to as ultra-heavysince its density may be considerably greater than that of the processfeed. For example, in some embodiments, when the incoming feed is an oilwith a density of 10-12 degrees API, not infrequently the API densityleaving the unit may be negative and may have a specific gravity greaterthan unity.

Any ultra-heavy bottoms from the processing unit may be fed to a cokingunit (a coker) where they may be thermally processed under even higherseverity to perhaps produce coke, and possibly additional lighter gasesand vapors. In some embodiments, a rotary unit (including an auger,e.g.) capable of continuous feed for achieving this function may perhapsbe appropriate for this application. Such a coker may be as described inU.S. Pat. No. 6,972,085. In other embodiments, should such a device notbe available or appropriate for use, either fluid coking or delayedcoking may be used instead. Regardless, the control afforded over theupstream processing may provide an enhanced degree of control over thequantity and quality of coke produced by the continuous coker.

In some embodiments, additional steps may be taken, depending perhaps onthe desired end product quality. The vapors leaving the coking unit andthe processing unit may be combined, perhaps recompressed (12), andmaybe then sent to a gas-liquid separation system (e.g., a condenser).In some embodiments, these vapors perhaps may be cooled by indirect heatexchange, possibly against cooling water, and the condensate may becollected in knock-out (KO) pots, perhaps either in stages or possiblyas a combined product. Perhaps depending upon system pressure andoverall economics, it may be feasible to recover by-product LPG at thisstage. Similarly, perhaps depending upon the operating severity of thedistillate recovery and the coking units, these vapors may possiblycontain significant quantities of olefins that in some embodiments maywarrant recovery as a process by-product. From this stage,non-condensable gases may flow to the hydrogen separation system (13)and the crude liquids may perhaps be sent to the product stabilizationunit (14). Such unit might saturate the olefins and di-olefins upon,perhaps, mildly hydrotreating of the naptha fraction.

In some embodiments, the gases entering the hydrogen separation systemmay consist predominantly of C₁ through C₄ hydrocarbons perhaps alongwith hydrogen, hydrogen sulfide, and traces of carbon oxides. Ashydrogen may be necessary for product stabilization, its recovery andrecycle here may be warranted. Hydrogen separation from the bulk gasmixture may be accomplished by compression (or re-compression) possiblyfollowed by either membrane separation or perhaps pressure-swingadsorption over five angstrom or smaller molecular sieves.

In some embodiments, off-gases from the hydrogen separation system, nowperhaps substantially depleted of hydrogen, and perhaps also depleted ofolefins and C₃ ⁺ components, may be processed further for additionalhydrogen possibly by either steam reforming or partial oxidation, or maypossibly be used as a fuel perhaps to power a small gas turbineproviding plant and/or electrolyzer power for hydrogen production, orpossibly may be flared. Depending upon perhaps the degree of priorprocessing and possibly the overall operating severity of the previoussteps, greater or lesser amounts of H₂S and acid gas removal may benecessary. The naphtha fraction (C₄ to 400 F) of the liquids producedmay contain olefins and di-olefins produced during processing in thedistillate recovery and coking units. These compounds may have to besaturated by hydrotreating prior to admission to a pipeline.

It should be noted that as many embodiments of the inventive technologyremove heavy, tarry substances (primarily as bottoms) from certain oils,such embodiments may find application wherever it is desired to clean anoil. As such, embodiments may find particular application in cleaning ofoil field tank bottoms.

It should be understood that, as mentioned, the inventive technologyincludes different embodiments, each relating to different combinationsof elements and features mentioned in this application. Suchelements/features include, but are not limited to: thermal environmentsin which a hydrocarbonaceous material may be heated to a certaintemperature and for a residence time; vapor and gas collection system(including a sweep gas system, as but one example); water removalsystems (which may simply be a thermal environment adapted to heat ahydrocarbonaceous material in a thermal environment to a specific liquidwater boiling temperature, perhaps for a specific residence time);stages that are each characterized by a specific thermal environment,where stages are serially established, with the thermal environments ofdownstream stages accepting as input at least a portion of the bottomsoutput by the thermal environment of an upstream stage, and withtemperatures of the thermal environments increasing with each successivestage; condenser(s), whether integrated as part of each thermalenvironment or established separately from a corresponding thermalenvironment, and whether acting on the vapors of one, some, or perhapseven all thermal environments; hydrotreater(s); hydrogen separationunit(s) that act on materials heated in thermal environment(s);sidestream fractioning apparatus (particularly where an oil to beprocessed into a less viscous condensate is withdrawn from asubstantially non-pumpable hydrocarbonaceous material such as extraheavy oil or bitumen); recycling apparatus (including, but not limitedto those apparatus adapted to deliver hydrogen for re-use, ornon-condensible gas yielded from a coking operation); those systemsadapted to continually input and/or output hydrocarbonaceous materials(as opposed to batch-mode processing); generating a diluent from thesame feedstock—a substantially non-pumpable one—to which it issubsequently added in order to prepare a pumpable oil; application oftechnologies (known and inventive) in the field (e.g., on the surface inthe vicinity of an oil extraction site such as an oil well). Indeed,certain embodiments of the inventive technology may relate tocombinations or permutations of all or only some of these—and perhapsother—features.

It should be noted that additional features and additional discussion offeatures disclosed herein may be found in Exhibit A, attached hereto,said exhibit incorporated herein by reference. Further, as thistechnical report presents observations based on processing responsedata, it focuses primarily only on specific application-type examples ofthe inventive technology. As such, it should be understood that,although the descriptions provided in Exhibit A may be couched inconstraining language that might appear to exclude alternatives, thisdescription is only of a specific embodiment(s) and should not precludein any manner the use of substitutes, nor preclude the omission ofcertain steps, devices or structures.

Of course, as oil processing technology is rather extensively developed,several aspects of known processing involve adjusting certain parameters(e.g., flow rate). In this sense, some aspects of the inventivetechnology continue is this “tradition”, and even reflect an advanceover oil processing adjustment technologies. Particularly, aspects ofthe present technology relate to a highly tunable system (or subsystems,such as one or more stages or the coking operation) where quantities andquality (e.g., viscosity) of outputs and products (e.g., condensate) canbe affirmatively controlled, and in perhaps predictable fashion, uponmanipulation of adjustable parameters (e.g., residence time and thermalenvironment temperature). In such a tunable system, residence times,temperatures, number of thermal environments, and/or flow rates (as buta few operational parameters) can be manipulated to yield vapors,condensate, coke, non-condensable gas, and/or bottoms as desired. One ofordinary skill in the art of oil processing would, upon reading thisspecification, know of at least one manner of making systems that allowfor the indicated adjustment or tuning capabilities.

It should be understood that this disclosure is intended to provide notonly adequate support for claimed subject matter as originally filed,but also for subject matter that has an intended purpose, goal orgeneral characterization that is different from that described in anypreambles of those originally filed claims. For example, certainembodiments that are indicated as relating to a viscosity reductionapparatus or method may also be usable in other (perhaps broader)contexts (e.g., merely distillate recovery, or oil processinggenerally).

It should also be understood that one of ordinary skill in the art ofoil processing—again, a highly developed art—would understand how tomake and use claimed subject matter upon reading this specification. Thetechnological advancements described and/or claimed herein are novel andnon-obvious, but how they are made and used may be well within the kenof a highly trained ordinary oil processing artisan after reading thisspecification. For example, thermally soaking a continuously input crudefeedstock to generate a hydrocarbonaceous material to be delivered to acoker may be novel and non-obvious, but manners of making and using sucha system, as claimed—including perhaps how to use boiling point curvesand other data assemblages (already known or perhaps provided herein) toestimate those temperatures and residence times that yield condensatefractions as desired—may be known to or readily ascertainably by one ofordinary skill in the art. Further, and as but one additional example,how to make that aspect of a system that reflects any descriptivelimitation of claimed subject matter relative to coordination of flowrates and volumetric capacities to yield residence times as intendedwould be within the ken of an ordinarily skilled oil processing artisanupon reading this description. Manufacturing certain claimed systems mayinvolve, in greater or entire part, merely well know piping,pressurization, heating, condensing, cooling, and other techniques—eventhough the systems themselves are inventive. It simply isimpractical—and unnecessary—to describe in detail how to make and useevery aspect of the inventive technology, particularly when the vastcapabilities of one trained in this extensively developed field wouldknow how to enable many of the features of claimed subject matter evenwithout reading the description (e.g., a material may be input viapiping).

As can be easily understood from the foregoing, the basic concepts ofthe present inventive technology may be embodied in a variety of ways.It involves both oil processing techniques as well as devices toaccomplish the appropriate processing. In this application, theprocessing techniques are disclosed as part of the results shown to beachieved by the various devices described and as steps which areinherent to utilization. They are simply the natural result of utilizingthe devices as intended and described. In addition, while some devicesare disclosed, it should be understood that these not only accomplishcertain methods but also can be varied in a number of ways. Importantly,as to all of the foregoing, all of these facets should be understood tobe encompassed by this disclosure.

The discussion included in this provisional application is intended toserve as a basic description. The reader should be aware that thespecific discussion may not explicitly describe all embodimentspossible; many alternatives are implicit. It also may not fully explainthe generic nature of the inventive technology and may not explicitlyshow how each feature or element can actually be representative of abroader function or of a great variety of alternative or equivalentelements. Again, these are implicitly included in this disclosure. Wherethe inventive technology is described in device-oriented terminology,each element of the device implicitly performs a function. Apparatusclaims may not only be included for the device described, but alsomethod or process claims may be included to address the functions theinventive technology and each element performs. Neither the descriptionnor the terminology is intended to limit the scope of the claims thatwill be included in any subsequent patent application.

It should also be understood that a variety of changes may be madewithout departing from the essence of the inventive technology. Suchchanges are also implicitly included in the description. They still fallwithin the scope of this inventive technology. A broad disclosureencompassing both the explicit embodiment(s) shown, the great variety ofimplicit alternative embodiments, and the broad methods or processes andthe like are encompassed by this disclosure and may be relied upon whendrafting the claims for any subsequent patent application. It should beunderstood that such language changes and broader or more detailedclaiming may be accomplished at a later date (such as by any requireddeadline) or in the event the applicant subsequently seeks a patentfiling based on this filing. With this understanding, the reader shouldbe aware that this disclosure is to be understood to support anysubsequently filed patent application that may seek examination of asbroad a base of claims as deemed within the applicant's right and may bedesigned to yield a patent covering numerous aspects of the inventivetechnology both independently and as an overall system.

Further, each of the various elements of the inventive technology andclaims may also be achieved in a variety of manners. Additionally, whenused or implied, an element is to be understood as encompassingindividual as well as plural structures that may or may not bephysically connected. This disclosure should be understood to encompasseach such variation, be it a variation of an embodiment of any apparatusembodiment, a method or process embodiment, or even merely a variationof any element of these. Particularly, it should be understood that asthe disclosure relates to elements of the inventive technology, thewords for each element may be expressed by equivalent apparatus terms ormethod terms—even if only the function or result is the same. Suchequivalent, broader, or even more generic terms should be considered tobe encompassed in the description of each element or action. Such termscan be substituted where desired to make explicit the implicitly broadcoverage to which this inventive technology is entitled. As but oneexample, it should be understood that all actions may be expressed as ameans for taking that action or as an element which causes that action.Similarly, each physical element disclosed should be understood toencompass a disclosure of the action which that physical elementfacilitates. Regarding this last aspect, as but one example, thedisclosure of a “condenser” should be understood to encompass disclosureof the act of “condensing”—whether explicitly discussed or not—and,conversely, were there effectively disclosure of the act of“condensing”, such a disclosure should be understood to encompassdisclosure of a “condenser” and even a “means for condensing” Suchchanges and alternative terms are to be understood to be explicitlyincluded in the description.

Any acts of law, statutes, regulations, or rules mentioned in thisapplication for patent; or patents, publications, or other referencesmentioned in this application for patent are hereby incorporated byreference. In addition, as to each term used it should be understoodthat unless its utilization in this application is inconsistent with abroadly supporting interpretation, common dictionary definitions shouldbe understood as incorporated for each term and all definitions,alternative terms, and synonyms such as contained in the Random HouseWebster's Unabridged Dictionary, second edition are hereby incorporatedby reference. Finally, all references listed in the list of ReferencesTo Be Incorporated By Reference In Accordance With The ProvisionalPatent Application or other information statement filed with theapplication are hereby appended and hereby incorporated by reference,however, as to each of the above, to the extent that such information orstatements incorporated by reference might be considered inconsistentwith the patenting of this/these inventive technology(s) such statementsare expressly not to be considered as made by the applicant(s).

Thus, the applicant(s) should be understood to have support to claim andmake a statement of inventive technology to at least: i) each of theprocessing devices as herein disclosed and described, ii) the relatedmethods disclosed and described, iii) similar, equivalent, and evenimplicit variations of each of these devices and methods, iv) thosealternative designs which accomplish each of the functions shown as aredisclosed and described, v) those alternative designs and methods whichaccomplish each of the functions shown as are implicit to accomplishthat which is disclosed and described, vi) each feature, component, andstep shown as separate and independent inventive technologys, vii) theapplications enhanced by the various systems or components disclosed,viii) the resulting products produced by such systems or components, ix)each system, method, and element shown or described as now applied toany specific field or devices mentioned, x) methods and apparatusessubstantially as described hereinbefore and with reference to any of theaccompanying examples, xi) the various combinations and permutations ofeach of the elements disclosed, and xii) each potentially dependentclaim or concept as a dependency on each and every one of theindependent claims or concepts presented.

In addition and as to computer aspects and each processing aspectamenable to programming or other electronic automation, the applicant(s)should be understood to have support to claim and make a statement ofinventive technology to at least: xii) processes performed with the aidof or on a computer as described throughout the above discussion, xiv) aprogrammable apparatus as described throughout the above discussion, xv)a computer readable memory encoded with data to direct a computercomprising means or elements which function as described throughout theabove discussion, xvi) a computer configured as herein disclosed anddescribed, xvii) individual or combined subroutines and programs asherein disclosed and described, xviii) the related methods disclosed anddescribed, xix) similar, equivalent, and even implicit variations ofeach of these systems and methods, xx) those alternative designs whichaccomplish each of the functions shown as are disclosed and described,xxi) those alternative designs and methods which accomplish each of thefunctions shown as are implicit to accomplish that which is disclosedand described, xxii) each feature, component, and step shown as separateand independent inventive technologys, and xxiii) the variouscombinations and permutations of each of the above.

With regard to claims whether now or later presented for examination, itshould be understood that for practical reasons and so as to avoid greatexpansion of the examination burden, the applicant may at any timepresent only initial claims or perhaps only initial claims with onlyinitial dependencies. Support should be understood to exist to thedegree required under new matter laws—including but not limited toEuropean Patent Convention Article 123(2) and United States Patent Law35 USC 132 or other such laws—to permit the addition of any of thevarious dependencies or other elements presented under one independentclaim or concept as dependencies or elements under any other independentclaim or concept. In drafting any claims at any time whether in thisapplication or in any subsequent application, it should also beunderstood that the applicant has intended to capture as full and broada scope of coverage as legally available. To the extent thatinsubstantial substitutes are made, to the extent that the applicant didnot in fact draft any claim so as to literally encompass any particularembodiment, and to the extent otherwise applicable, the applicant shouldnot be understood to have in any way intended to or actuallyrelinquished such coverage as the applicant simply may not have beenable to anticipate all eventualities; one skilled in the art, should notbe reasonably expected to have drafted a claim that would have literallyencompassed such alternative embodiments.

Further, if or when used, the use of the transitional phrase“comprising” is used to maintain the “open-end” claims herein, accordingto traditional claim interpretation. Thus, unless the context requiresotherwise, it should be understood that the term “comprise” orvariations such as “comprises” or “comprising”, are intended to implythe inclusion of a stated element or step or group of elements or stepsbut not the exclusion of any other element or step or group of elementsor steps. Such terms should be interpreted in their most expansive formso as to afford the applicant the broadest coverage legally permissible.

Finally, any claims set forth at any time are hereby incorporated byreference as part of this description of the inventive technology, andthe applicant expressly reserves the right to use all of or a portion ofsuch incorporated content of such claims as additional description tosupport any of or all of the claims or any element or component thereof,and the applicant further expressly reserves the right to move anyportion of or all of the incorporated content of such claims or anyelement or component thereof from the description into the claims orvice-versa as necessary to define the matter for which protection issought by this application or by any subsequent continuation, division,or continuation-in-part application thereof, or to obtain any benefitof, reduction in fees pursuant to, or to comply with the patent laws,rules, or regulations of any country or treaty, and such contentincorporated by reference shall survive during the entire pendency ofthis application including any subsequent continuation, division, orcontinuation-in-part application thereof or any reissue or extensionthereon.

I. U.S. Patent Documents DOCUMENT NO. PUB'N DATE PATENTEE OR & KIND CODEmm-dd-yyyy APPLICANT NAME 1,817,926 08/11/1931 McIntire 2,657,12010/27/1953 Bigsby et al. 4,125,437 02/14/1978 Bacon 4,200,517 04/29/80Chalamers, et al. 4,219,405 08/26/80 Pietzka 4,822,479 04/18/89 Fu, etal. 5,259,945 11/09/93 Johnson, Jr. et al. 5,318,697 06/07/1994 Paspeket al. 5,645,712 07/08/97 Roth 5,653,865 08/05/97 Miyasaki 5,753,08605/19/98 Guffey, et al. 5,755,389 05/26/98 Miyasaki 5,836,524 11/17/1998Wang 6,972,085 12/06/2006 Brecher

II. Foreign Patent Documents Foreign Patent Document Country Code,Number, PUB'N DATE PATENTEE OR Kind Code (if known) mm-dd-yyyy APPLICANTNAME WO 95/13338 05/18/1995 Western Research Institute WO 01/3845805/31/2001 Western Research Institute CA 2153395 02/09/1999 WesternResearch Institute

III. Other Documents Giles, K. A. Fundamentals of Petroleum RefiningUnited States Patent Application, 60/167,337, “Methods and Apparatus forHeavy Oil Upgrading”, filed Nov. 24, 1999. United States PatentApplication, 60/167,335, “Methods and Apparatus for Improved Pyrolysisof Hydrocarbon Products”, filed Nov. 24, 1999. United States PatentApplication, 60/633,856, “Methods and Apparatus for Producing Heavy Oilfrom Extra-Heavy Feed Oils”, filed Dec. 6, 2004 United States PatentApplication, 60/633,744, “Distillate Recovery Methods and Apparatus forOil Processing Applications”, filed Dec. 6, 2004

Exhibit A Introduction

During early evaluations for possibly inventive technologies, thermalprocessing units were presumed to

function as a vacuum still to thermally separate the higher and lowerboiling fractions of the incoming feed. Operating in this fashion (i.e.,considering boiling processes alone), the unit would collectapproximately 20% of a Cold Lake crude as an overhead distillate whilethe remaining 80% would be bottoms to be fed to the continuous coker.Using improved, novel technologies, product samples were generated byoperating bench-scale equipment that simulated the inventive methods. Sodoing, we observed overhead yields from the DRU of greater than 30% byweight rather than the 20% indicated by boiling considerations alone.

Not only were we able to produce these greater yields, but we were alsoable to do so at what amounted to nearly constant overhead productquality. As the figure to the left shows, product quality, at leastquality as measured by the density and viscosity of the overheaddistillate, remains substantially constant as processing severity (hereexpressed as the distillate recovery unit top temperature) is increased.On the other hand, product quality of the bottoms product, againmeasured relative to these same two parameters, is seen to be decreasingwith increasing processing severity.

In order to understand the origin and fate of this additional material,differential mass balances by boiling point range were calculated. Theresults are shown in the figure to the right. Note the excellentquantitative agreement between the cumulative distributions in thefigure and the overhead yields obtained during stability study.

As the figure shows, relative to the feed oil, the DRU products areenriched in materials boiling below 850_F and depleted in materialsboiling above 850_F. The DRU is functioning not only as a device forphysically separating the oil on the basis of its constituent's boilingpoints, but also as a chemical reactor. As such, the yield of distillatematerial collected overhead will be dependent not only on thetemperature and temperature profile of the DRU, but other variables suchas residence time and sweep gas composition. A program to understand andexploit this phenomena is underway and this report contributesengineering data towards understanding the phenomena involved.

The test results described in this report were obtained using WRI's onebarrel per day DRU located at the company's Advanced Technology Centernorth of Laramie, Wyo. A schematic of the equipment appears below. Theoils tested consisted of both diluted and undiluted crudes obtained bythe MEG Energy Corporation from various Canadian oil sands operations.All of the chemical analyses reported in this document were performed bystaff of the National Centre for Upgrading Technology (NCUT) in Devon,Alberta, Canada, under the very capable supervision of Dr. ParvizRahimi.

It should be understood that, although the descriptions provided hereinmay be couched in constraining language that might appear to excludealternatives, this description is only of a specific embodiment(s) andis not intended in any manner to preclude the use of substitutes norpreclude the omission of certain steps, devices or structures. WRI usesbench-scale test equipment to determine the compositions and yields ofproducts expected when processing various crudes with the WRITE process.This bench scale equipment consists of three separate hardwarearrangements, a one barrel per day facility designed to simulate thedistillate recovery unit (DRU) of the WRITE process and both two-inchand six-inch inclined rotary screws designed to simulate the continuouscoker. A schematic of the bench-scale laboratory equipment used tosimulate the flash and stripper units of the DRU appears above.

As shown, heavy oil flows from a feed tank into a pump that pressurizesthe material into an electrically heated feed pre-heater (stripper unit1). A pressure let-down valve (flash valve) controls the pressure. Aseparator is used to remove water by removing water vapors overhead andcondensing them in KO-1 as Product 1. The liquid hydrocarbons and solidsflow successively from the bottom of the flash tank into four strippingunits. Each of the stripping units is an electrically heated vessel withits own temperature controller, sweep gas provisions, and provisions forproduct recovery. Any gases produced in any of the heated vessels can besampled and analyzed. The material of construction used throughout thesystem is type 316 L stainless steel. This selection was in partdictated by the fact that some of the feedstocks used in earlierinvestigations contained high concentrations of chlorides and sulfur.Previous refinery experience indicates that type 316 L is adequate forthis service. The test unit is capable of stripping at temperatures upto 750_F. All flows in and out of the bench-scale test unit aremonitored and continuously logged. Similarly, all temperatures andpressures throughout the unit are continuously logged.

First Test Series—Undiluted Bitumen

Carbon Dioxide & Methane Sweep Gases and Differing Space Velocities

The Compatibility and Stability Study was a Jointly Sponsored ResearchProject (Task 28 under USDOE contract DE-FC26-98FT40323) conductedcollaboratively with the National Centre for Upgrading Technologylocated in Devon, Alberta, Canada. The test program required thegeneration of overhead samples produced at DRU Stage 5 temperatures of650° F., 675° F. and 700° F. The overhead yields observed during theproduction of these samples are plotted on the accompanying chart. It iseasily seen that these yields are significantly above those one wouldpredict on the basis of distillation alone.

Analytics supported by differential mass balance calculations confirmedthat, relative to the feed oil, the DRU products are enriched inmaterials boiling below 850° F. and depleted in materials boiling above850° F. The DRU is functioning not only as a device for physicallyseparating the oil on the basis of its constituent's boiling points, butalso as a chemical reactor. As such, the yield of distillate materialcollected overhead will be dependent not only on the temperature andtemperature profile of the DRU, but other variables such as spacevelocity and sweep gas composition. With this in mind, a second researchprogram was initiated to explore and understand the phenomena underlyingthese observations.

As the Stability Program was conducted using undiluted bitumen fromEnCana's Foster Creek operations, more oil from the same source wasacquired for conducting the DRU optimization studies. Even though thecrude was supplied by the same producer from the same formation, thefirst experiment was to run at the same conditions as those employed inthe earlier study in order to discern the discrepancies, if any, betweenthe DRU running on the two different feedstocks. The results of this runand a replication, using carbon dioxide as the sweep gas, are summarizedin the table below. These results duplicate those observed previouslyduring the Compatibility and Stability study. Note also the excellentmaterial balance closure, generally 2.5%. CO₂ Sweep Gas & High SpaceVelocity Test 1a Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Closure, %Temperature, _F. 338 471 612 661 704 Cumulative Yield, % 3.17 3.48 11.2519.41 33.95 99.88 Test 1b Stage 1 Stage 2 Stage 3 Stage 4 Stage 5Closure, % Temperature, _F. 338 473 612 662 706 Cumulative Yield, % 2.493.11 11.23 19.16 34.44 97.55

When the carbon dioxide is replaced with methane as the sweep gas, theresults tabulated below are obtained. Examination shows that theseclosely replicate those results obtained using CO₂ as the sweep gas. CH₄Sweep Gas & High Space Velocity Test 3a Stage 1 Stage 2 Stage 3 Stage 4Stage 5 Closure, % Temperature, _F. 333 469 607 657 703 CumulativeYield, % 2.13 2.38 11.57 19.08 34.01 98.77 Test 3b Stage 1 Stage 2 Stage3 Stage 4 Stage 5 Closure, % Temperature, _F. 342 466 607 657 704Cumulative Yield, % 1.91 2.92 11.74 18.48 32.93 98.07

At high space velocities, there is no statistical difference between theDRU overhead yields obtained using either methane or carbon dioxide asthe sweep gas. As these two gases differ significantly in their chemicalbehavior, it is unlikely that the increased yields observed are a resultof liquid interactions with the sweep gas. It is much more likely thatthese increases are associated with lowered space velocities through theDRU. This assumption is tested in the next series of tests.

Returning to CO₂ as the sweep gas and lowering the space velocityproduces the results summarized below. The cumulative yields have nowincreased significantly above those for the higher space velocity. CO₂Sweep Gas & Lowered Space Velocity Test 2a Stage 1 Stage 2 Stage 3 Stage4 Stage 5 Closure, % Temperature, _F. 335 467 621 663 697 CumulativeYield, % 1.67 3.39 15.61 25.15 38.87 101.16 Test 2b Stage 1 Stage 2Stage 3 Stage 4 Stage 5 Closure, % Temperature, _F. 329 464 622 660 697Cumulative Yield, % 2.6 3.08 17.45 26.95 41.43 101.34

Using methane as the sweep gas confirms that the enhanced yields areindependent of the sweep gas. CH₄ Sweep Gas & Lowered Space VelocityTest 4a Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Temperature,_F 337 468620 658 701 Closure, % Cumulative Yield, % 2.12 2.21 17.07 26.24 48.3197.28 Test 4b Stage 1 Stage 2 Stage 3 Stage 4 Stage 5

Temperature,_F 337 468 620 658 701 Cumulative Yield, % 2.68 3.04 17.7226.82 46.12 97.69

Although possessing a little more scatter than the results obtained fromthe Compatibility and Stability Program or those obtained at the higherspace velocity, these results convincingly demonstrate that theincreased yields are, in fact, a consequence of the lower space velocityand are independent of the sweep gas composition.

The figure above summarizes the results of a 2×2 matrix withreplications—that is to say that two sweep gases were employed at twospace velocities and each of those four tests was replicated. Analysisshows that overall DRU yield depends upon the stage temperature andspace velocity, but not upon the sweep gas.

Representative samples from each of these overheads were analyzedchemically, and the results are summarized below. Once again, thereappears to be no difference between the overhead products made using onesweep gas or the other, and there is little or no difference betweenthose produced at higher or lower space velocities. Properties of theDRU Overhead Products High Space Velocity Lower Space Velocity PropertyCO₂ CH₄ CO₂ CH₄ Carbon, wt % 84.68 84.50 84.38 84.41 Hydrogen, wt %12.80 12.84 12.91 13.04 Nitrogen, wt % 0.12 0.15 0.12 0.11 Sulfur, wt %2.75 2.94 2.82 2.81 Diene Value, g I₂/100 g 1.70 1.64 1.49 1.91 PourPoint, _C. −60 −33 −48 −54 Density, _API 24.34 24.07 24.76 24.15Viscosity @ 20_C., cSt 18.311 17.012 14.453 17.792 P Value 3.1 4.62

While the DRU operating conditions examined to date do not seem toinfluence the quality of the overhead product, the same is not true ofthe bottoms products. Properties of the DRU Bottoms Products High SpaceVelocity Lower Space Velocity Property CO₂ CH₄ CO₂ CH₄ Carbon, wt %85.58 84.80 85.26 84.64 Hydrogen, wt % 9.08 9.24 9.24 8.22 Nitrogen, wt% 0.96 0.90 0.59 1.07 Sulfur, wt % 5.17 5.29 5.18 5.28 Diene Value, gI₂/100 g 17.56 13.2 16.29 10.77 Density, _API 5.08 4.69 3.65 1.61Viscosity @ 100_C., cSt 698 752 1190 1010 P Value 1.82 2.06 1.38 1.12SARA, wt % Saturates 11.93 12.63 12.10 12.20 Aromatics 39.94 39.94 38.2835.84 Resins 24.80 25.37 23.16 20.25 C₅ Asphaltenes, wt % 23.33 22.0626.46 31.71 Metals, ppm Al 12.4 9.0 10.5 12.8 Ba 2.7 1.6 1.9 2.3 K 5.3<0.8 1.9 2.3 Ca 68.3 36.9 42.8 55.8 Fe 18.6 7.4 10.5 14.0 Mg 10.6 5.77.6 9.3 Mn <0.9 <0.8 <1.0 <1.2 Na 48.8 33.6 38.1 52.3 Ni 108.2 105.0118.1 131.4 Si 18.6 10.7 18.1 18.6 Ti 3.6 2.5 2.9 3.5 V 287.4 283.0317.1 353.6

The bottoms produced at the lower space velocity are more dense and moreviscous than those produced at the higher space velocity and they havelower P values, indicating a greater degree of thermal deterioration.Again, consistent with their thermal history, they are lower inaromatics and resins and have higher asphaltene concentrations.

Analyses performed on the naphtha fraction of the DRU overheads aresummarized below. Although more data is needed before definitiveconclusions can be drawn, one could argue that the use of a CO₂ sweepgas rather than methane produced more naphtha at both space velocitiesand that the naphtha was more aromatic and less olefinic when carbondioxide was used. Properties of the DRU Overhead Naphtha Fractions HighSpace Velocity Lower Space Velocity Property CO₂ CH₄ CO₂ CH₄ Yield, wt %8.5 8.0 8.8 7.3 Composition, vol % Aromatics 16.0 14.1 19.7 15.5 Olefins29.0 33.3 26.7 29.5 Saturates 55.0 52.6 53.7 55.0 Bromine Number, 46.250.6 48.9 50.6 g Br_(2/)100 gA Final Test Using Undiluted Bitumen

The remaining undiluted bitumen was used to extend the data generatedearlier. Testing to this point had been based upon the compatibilitystudy space velocity, herein designated as SV. The lowered spacevelocity runs were made at a value which was 60% of SV. The finalmaterial was used at a space velocity that was 30% of SV and the resultsof that test (Test C) are shown below. The trend clearly continues.

Test C Results

Table 3 summarizes the results for Test C and the figure above shows aplot of these results and their comparison with the results of previousstudies. Power regression curves have been used to smooth the data forthe Test C yield vs. temperature plot and for the undiluted feedsimulated distillation curve. The lower of the unsmoothed plots is theyield vs. temperature curve obtained during the stability andcompatibility study conducted with NCUT and reported at the 225^(th)American Chemical Society meeting in New Orleans, Mar. 23-27, 2003. Theupper of the unsmoothed curves is data obtained during furtherUSDOE-sponsored research and reported at the 3^(rd) NCUT Meeting onUpgrading and Refining of Heavy Oil, Bitumen, and Synthetic Crude Oil inEdmonton, Alberta, on Sep. 23, 2003. As noted, the trend of increasingyield with increasing process severity remains intact. TABLE 3Production by Stage for Run C KO #1 KO #2 KO #3 KO #4 KO #5 Total Total2.45 0.49 10.78 4.05 7.74 25.51 Wt % of Feed 4.34 0.87 19.10 7.18 13.7145.20 Cumulative 4.34 5.21 24.31 31.48 45.20

Second Test Series Diluted Bitumen

Analysis of the Starting Crudes

The oils tested were supplied by MEG Energy Corporation and wereobtained from EnCana's Foster Creek operations. Both diluted andundiluted crudes were tested. The analysis of each appears below.Analysis of Crude Oils Tested With Diluent Without Diluent Elemental, wt% C 84.05 H 10.44 N 0.27 S 4.27 4.5 Water, wt % 0.372 3.675 PI, wt %14.1 17.52 HI, wt % 9.89 TI, wt % 0.01 0.03 MCR, wt % 11.85 13.24 BSW,wt % 0.2 5.3 Pour Point, _C. −15 18 Density (API) 0.9624 (15.39) 0.997(10.43) Viscosity, cSt 60, _C. 214.16 2099 80, _C. 84.66 502.7 100, _C.41.06 173.5 SARA, wt % Asphaltenes (C₅) 17.52 Saturates 20.60 Aromatics47.31 Polars 14.57 Metals, ppm Ni 58.4 V 155.8

Simulated distillations were performed on both crudes and the resultsare shown on the next page. Not unexpectedly, the diluted oil has an IBPsome 300_F below that of the undiluted oil. At temperatures above 500_F,the curves become parallel suggesting that all of the diluent has beenremoved by this temperature. The diluted oil was said to contain anominal 20% by weight of condensate, however, if one takes the boilingpoint curve for the diluted oil and subtracts nine weight percent fromthe quantity overhead, the boiling point curve for the undiluted oil isduplicated nicely. This correspondence is shown on the second curve onthe following page.

Summary of Results

Experimental runs were conducted at two stage 5 temperatures, 650° F.and 675° F. using both diluted and undiluted feeds. Composite overheadsamples consisting of the total material collected from each of

the knock-out pots during the test interval were produced and sent foranalysis. Detailed log sheets and operating summaries are contained inthe Appendix. A summary of the test conditions under which the overheadoils were produced is summarized below. Material balance closures wereless than desired, but usable. Operating severity increases as one movesfrom Test A1 (least severe) to Test C (most severe). TABLE 2 Summary ofTest Runs Diluent Feed Overhead Collected Bottoms Loss Closure Run Y/NTemperature_F. lbs KO 1 & 2 KO 3-5 lbs lbs % A1 Y 650 70.05 4.89 17.1845.43 2.55 96.4 B2 Y 675 36.80 1.65 18.72 10.43 6.00 83.7 C N 675 56.442.94 22.57 27.03 3.90 93.1

The product collection system in the mini-WRITE unit was not designed tocollect diluent, thus vapors non-condensible at room temperature and 12psia are lost. This is, in part, responsible for the poorer materialbalance closure observed. Test C, however, employed undiluted feed, andthe compositions obtained from this run are representative of systemperformance under conditions of the test. Test B2 differs only from TestC in the use of diluted rather than undiluted feed. Its generallylighter composition,

relatively greater amounts of naphtha and lessor amounts of gas oil, isconsistent with at least some of the diluent being collected along withthe product oils. Test A1, being conducted under the least severeconditions, produced the least amount of overhead oil, and thus basedupon a constant diluent fraction recovered, contains the greatestproportion of diluent in its product. Interpretations of the crudeassays should bear these considerations in mind. TABLE 4 Production byStage for Run A1 KO #1 KO #2 KO #3 KO #4 KO #5 Total Total 4.09 0.807.88 3.62 5.68 22.07 Percentage 5.84 1.14 11.25 5.17 8.11 31.51Cumulative 5.84 6.98 18.23 23.40 31.51 Adding “Lost Diluent” Total 5.3652.075 7.88 3.62 5.68 24.62 Percentage 7.66 2.96 11.25 5.17 8.11 35.15Cumulative 7.66 10.62 21.87 27.04 35.15

TABLE 5 Production by Stage for Run B2 KO #1 KO #2 KO #3 KO #4 KO #5Total Total 1.65 0.00 9.60 2.75 6.37 20.37 Percentage 4.48 0.00 26.097.47 17.31 55.35 Cumulative 4.48 4.48 30.57 38.04 55.35 Adding “LostDiluent” Total 4.65 3.00 9.60 2.75 6.37 26.37 Percentage 12.64 8.1526.09 7.47 17.31 71.66 Cumulative 12.64 20.79 46.88 54.35 71.66

Results from Tests A1 & B2

Tables 4 and 5 summarize the results for Tests A1 and B2 and FIGS. 8 & 9show the variation of yields with temperature. One of the most strikingcharacteristics of FIG. 8 is the fact that the overall yields from TestsA1 and B2 fall below the simulated distillation boiling point curve attemperatures below 450_F. This is coupled with the fact that Table 2shows that 2.55 lbs of material are unaccounted in Test A1 and 6.00 lbswere unaccounted in Test B2. Table 4 is composed of two parts. The upperpart records the weight of product actually collected from knock-outpots 1-5 and calculates the percentage overhead based upon these weightsand the feed rate. This is the material that was analyzed in the crudeassay. The bottom portion of Table 4 assumes that the 2.55 lbs ofunaccounted material was noncondensible or “lost” diluent that given aproper recovery system would have reported to knockout pots 1 & 2. Ifso, and assuming a 50-50 distribution between the two knockouts, thebottom portion of Table 4 can be computed. This is the curve just abovethe simulated distillation curve in FIG. 9. The excellent agreement withthe simulated distillation curve suggests that this is a plausibleexplanation.

Similarly if the 6.00 lbs of unaccounted material in Test B2 is assumedto be “lost diluent” and apportioned 50-50 between knockouts 1& 2, thebottom portion of Table 5 results. This is shown as the uppermost curvein FIG. 9, once again suggesting that this is a plausible explanation.As has been consistently observed, increases in processing severityresult in increases in mass fraction reporting to overhead product atall temperatures. Test A1 was one of three tests conducted at theconditions indicated in Table 2. When all of this data is combined, thecurves in FIG. 10 result. This figure suggests that the most plausibleexplanation for the lower closure on the material balances was theinability of the product collection system to condense all of thediluent flowing overhead. Similarly after accounting for diluent in theproduct oils, FIG. 10 once again confirms the increased yields obtainedwith increasing processing severity.

Third Test Series

Low Space Velocity Exploration DRU Design & Optimization

Equipment Preparation & Acquisition of Design Data for the DistillateRecovery Unit

Work on the project began with preparing the Mini-WRITE experimentalfacilities for bench scale testing. Task 1 involves operation of themini-WRITE system to produce data for the reference design of thedistillate recovery unit (DRU). Past upsets in the operation of theMini-WRITE reactor resulted in plugging, overflowing, and gunking up ofstage five. Coke built up in the heater elements, possibly reducingtheir efficiency. Similarly, the feed pump used for the earlier seriesof tests was inadequate for feeding higher viscosity oil and fordelivering oil consistently at reduced feed rates. In addition to this,leak testing, instrument calibration and routine system overhaul arenormal components of maintaining and readying the unit for service.

Installation of the new pump. The peristaltic pump was installed intothe system and preliminary tests verified its ability to achieve lowfeed rates. Using settings of 1, 1.5 and 2.0 on the motor speedcontroller (full speed is 10), the pump discharged at rates of 0.1, 0.64and 0.97 bbl/day, respectively. These tests were done with water andused 0.25-inch I.D. tubing Our initial experience with the pumpindicated that it can deliver between 5 and 60 lbs of oil per hour attemperatures up to 250_F, which is well within the requirements for ourexperimental matrix. During testing, the pump delivered a flow rate of5.8 lbs per hour over a six-hour period with less than a 1% deviation inrate, which far exceeds the accuracy of the previous gear pump. We alsofound that the pump was capable of delivering the oil at ambienttemperature, so preheating was unnecessary.

In sizing the pump, it was necessary to measure viscosity-temperaturecurves for the Canadian crude oils (both raw and with added diluent)that we currently have in inventory. Data for the raw crude wasavailable from NCUT's analysis for our previous tests. Viscosity datafor the crude oil with diluent was developed in-house and the resultingviscosity curves have been included in the project files. Besides pumpsizing, these curves were useful in determining correct oil feed ratesfor the Mini-WRITE reactor.

System Overhaul. We stripped the outer insulation and drained oil fromthe Mini-WRITE reactor so that leak tests could be conducted and reactorstage five could be cleaned. All five stages of heavy oil that remainedfrom the previous series of tests were drained and flushed with dieseloil. The individual load cells used to weigh overhead product from eachstage were calibrated. The scales used to measure the feed and bottomoil weights were checked. Stages one through four, their associatedvapor recovery systems, and the gas collection system were tested forleaks. A major leak was found and corrected in stage three's vaporrecovery plumbing. A leak was also found and corrected in the tubingleading to the gas bubblers. These are located downstream of the flowtotalizer and used to maintain proper flow of gas from the reactor. Withthe leaks corrected, the system was pressurized to approximately fivepsig and allowed to remain for several hours. No pressure drop was notedwhich indicated a leak-free system. Calibration of the gas flowindicators was then completed.

Refurbishing Stage 5. In the process of inspecting the interior ofreactor five, we discovered that a thick layer of coke had completelyencased its heating elements and appeared to cover the lower half of thehorizontal tank. In this condition, the heater could not be removed andit was not possible to free it by simply chipping away the coke. Analternative was to raise the temperature of the heater and oxidize thecoke by admitting a limited quantity of air. This would be a timeconsuming process because the rate of coke oxidation must be controlledto prevent run-away combustion that would destroy the heating elementand possibly damage its surrounding tank.

We attempted to oxidize the coke by warming heater five to 400_F andadmitting one-to-two liters per minute of air. We planned to do this forapproximately two days and subsequently inspect heater five to see if asignificant quantity of coke had been removed. If not, heater-tankassemblies two and five would be exchanged. After about one day ofoperation, it became clear that this process would not be effective. Wealso discovered that stages two and five could not be easilyinterchanged because various fittings had been welded onto stage five.At that point it was decided to cut open stage five's horizontal tankand attempt to manually remove the coke. We cut open the reactor andwere able to separate the two halves exposing a heavily coked heaterassembly. We were then able to chip much of the coke from the heater andtoluene was used to remove the remaining oil/coke mixture. Thisprocedure left the heater and tank substantially free from coke and theheater's elements in excellent condition. The stage five reactor wasthen welded back together and integrated back into the system. Theheater was tested and operated properly. Leak tests of stage five andassociated plumbing were then completed. As part of the reassemblyprocess, two additional thermocouple ports were added to allow themeasurement of oil temperature within stage five. The thermocouples werelocated at the mid-point of the reactor and approximately three inchesfrom the discharge point. Both were positioned so that they would becompletely immersed in oil during system operation.

Improvements to the product recovery and ventilation system. The productcollection system in the mini-WRITE unit was not designed to collectdiluent, thus in earlier experiments, vapors non-condensible at roomtemperature and 12 psia were lost. This was, in part, responsible forthe poorer material balance closures observed earlier. To overcome thisdeficiency, the efficiency of the laboratory ventilation system wasupgraded. Bell assemblies located at the end of suction lines nowcapture the fugitive vapors that are produced when the overhead pots aredrained into collection pans for transfer. In addition, new stainlesssteel collection pans with handles and lids are being used. The lidshelp reduce the release of vapors into the laboratory as the overheadcondensate is transferred to the composite sample drums, and the handlesfacilitate transferring the condensate. An HVAC consultant, IndependentHeating, suggested methods to improve overall ventilation. Thecontractor installed a larger motor into the facility's exhaust systemthereby significantly increasing the extraction rate of fugitive vaporsfrom the Mini-WRITE facility.

Operational Status. The Mini-WRITE reactor began the DRU test series onOctober 24 at 11:00 pm and completed a successful series of tests onOct. 29, 2004. Samples were then labeled, packaged and sent to theNational Centre for Upgrading Technology (NCUT) for analysis. TheMini-WRITE unit was then drained, inspected, leak tested and placed incold stand-by. There has been no further activity with this equipment.Analytic results from the October test series have been received fromNCUT and an engineering analysis of the system operation is presented inthe work that follows.

Six runs were conducted with space velocities that varied from 18% to100% of that used in the Stability and Compatibility Study and aprogression of increasing overhead yields with diminishing spacevelocities was observed. The data showed indications of asymptoticallyconverging yields at the lower space velocities and in one instance ayield curve that fell below the simulated distillation curve at thehigher space velocity.

Both of these observations are explicable. Space velocity and residencetime are inverse relationships and increasing space velocity correspondsto a decreasing residence time. As residence time diminishes, thethermal load on the product recovery system is increased, and additionalmaterial, especially diluent and the lighter hydrocarbon fractions, canpass through the product recovery system and fail to be recovered. Thisis analogous to the data described earlier in this report where it wasnecessary to estimate diluent losses in the product recovery system inorder to explain the yield curves obtained. The product crude assaysshould be viewed with the knowledge that the resultant oils might be alittle heavier than they otherwise would have been because of thispossible loss of light ends.

Similarly as space velocity is diminished, residence time is increased.While the overall total production of light oil is a monotonicallyincreasing function of residence time, the rate of light oil productionis not. As in most kinetic studies, the rate decreases with extent ofreaction, leading to the observed asymptotic convergence of the yields.As the yield versus space velocity curve is a kinetic plot, the overallintegral rates of reaction can be determined from the data. So doingproduces the plot shown below.

A clear maximum exists in the curve of light oil production rate versusspace velocity, and it is at a normalized space velocity ofapproximately 0.3. Although one could continue to operate at residencetimes longer than this, such activity does not represent the best use ofoverall reactor volume, and operation at the maximum rate is preferred.

Overhead Distillate Product Quality

Consistent with earlier observations, DRU distillate overhead quality asmeasured by its API gravity and kinematic viscosity is not a function ofprocessing conditions. This observation now extends to the compositionalanalysis as well where crude assays indicate no significant differencesbetween the boiling point fractions and no sample-to-sample differencesseem to exist between saturate, aromatic and olefin concentrationspresent in various boiling point cuts.

This is encouraging as, although, overhead quality in not dependent uponoperating conditions, the rate of material generation is. Since productquality is independent of the rate of generation, the DRU can bedesigned with maximum throughput in mind. Properties of the DRUOverheads Analysis 0.18*(SV) 0.30*(SV) 0.36*(SV) 0.40*(SV) API Gravity,deg 27.25 27.93 27.98 29.21 Pentane Insoluble, wt % .005 .015 .02 0Toluene Insoluble, wt % 0 .01 0 0 Pour Point, _C. −48 <−80 −60 <−80 TAN,mg KOH/g oil 0.44 0.64 0.469 0.538 Kinematic Viscosity, cSt 20 _C. 8.8178.239 7.066 6.519 40 _C. 4.818 4.566 4.475 3.843 50 _C. 3.783 3.6183.597 3.049

Properties of the DRU Bottoms Analysis 0.18*(SV) 0.30*(SV) 0.36*(SV)0.40*(SV) Density, g/cc 1.086 1.132 1.134 1.134 API Gravity, deg −1.21−6.50 −6.72 −6.72 I_(N) 41.6 43.65 49.0 42.7 S_(BN) 98.9 126.6 128.4120.4 P-Value 2.38 2.90 2.62 2.82

CONCLUSIONS

-   -   Overhead yields of distillate product obtained from the        Distillate Recovery Unit (DRU) are independent of the sweep gas        employed in the unit, at least for this combination of oxidized        (CO₂), reduced (CH₄), and inert (N₂) gases.    -   Overhead yields are dependent upon the space velocity and the        stage temperatures employed in the DRU, increasing with        increasing temperature and increasing with decreasing space        velocity.    -   A maximum in the distillate production rate occurs at a space        velocity that is 30% of the one used in the Stability and        Compatibility Study.    -   The API gravity and kinematic viscosity of the overhead product        is nearly constant, regardless of conditions used for its        production. API gravities range from 27 to 30_API and        viscosities range from 6 to 9 cSt at 20_C. Canadian pipeline        specifications require an API gravity of 19_or lighter and a        viscosity at pipeline temperatures of 350 cSt or less. The DRU        overhead product easily conforms to these specifications.    -   The composition of the DRU overhead oil is 10-15 wt % naphtha,        50-60 wt % distillate, 25-30 wt % gas oil, and less than 1 wt %        resid.    -   The naphtha fraction of the product oil contains 10-20 wt %        olefins, 15-20% aromatics and 65-70 wt % saturates. The        distillate fraction contains 5-10 wt % olefins, 35-40 wt %        aromatics and 50-55 wt % saturates.

Bottoms from the DRU become heavier and more viscous as processingseverity is increased. Appendix Product Quality Information Crude AssayResults for 0.18*(SV) Test Stage 4 Temperature = 592 _F. IBP to 200 _C.200 to 350 _C. 350 to 500 _C. >500 _C. % weight 11.8 56.1 31.5 0.6density 0.7787 0.893 0.9354 API gravity 50.04 26.8 19.63 S, % w 1.582.38 3.01 N, mg/l 35.54 226.8 ppm 0.17 wt % C 84.36 84.34 84.56 H 13.5512.36 11.8 H/C 1.91 1.75 1.66 Mercaptans, % w Aromatics, % v 17.4 41.5Olefins, % v 18.1 9.6 Saturates, % v 64.5 48.9 Aniline Point, _C. 50.157.4 Viscosity, 40 _C. 4.702 Viscosity, 50 _C. 3.52 22.962 Viscosity,100 _C. 4.778 D86 T10, _C. 249.5 D86 T50, _C. 294.3 D86 T80, _C. 314.7D86 T90, _C. 326.5 US Cetane 39.8 Canadian Cetane 36.0 Cloud Point, _C.−43 Freezing Point, _C. −35.2 Pour Point, _C. −51 −63 TAN, mg KOH/g0.401 0.547 D1160 Vol 10, _K 641.7 D1160 Vol 50, _K 661.4 D1160 Vol 90,_K 703 TBP, _K 666.8 K factor 11.36 Pentane Insoluble, % w 0.01 Ash Fe<1 Ni <1 V <1 MCRT, % w .01 Crude Assay Results for 0.24*(SV) Test Stage4 Temperature = 600 _F. IBP to 200 _C. 200 to 350 _C. 350 to 490_C. >490 _C. % weight 12.4 58.2 28.7 0.7 density 0.7793 0.8875 0.9299API gravity 49.9 27.78 20.52 S, % w 1.41 2.07 2.84 N, mg/l 23.08 159.7ppm 0.15 wt % C 83.23 84.85 84.58 H 13.45 12.72 11.86 H/C 1.93 1.79 1.67Mercaptans, % w Aromatics, % v 17.2 39.9 Olefins, % v 15.8 6.9Saturates, % v 67.0 53.2 Aniline Point, _C. 51.8 58.6 Viscosity, 40 _C.4.108 Viscosity, 50 _C. 3.464 19.053 Viscosity, 100 _C. 4.297 D86 T10,C. 246.2 D86 T50, C. 286.3 D86 T80, C. 308.5 D86 T90, C. 322.4 US Cetane39.9 Canadian Cetane 37.3 Cloud Point, _C. −38 Freezing Point, _C. −42.8Pour Point, _C. −51 −21 TAN, mg KOH/g 0.381 0.671 D1160 Vol 10, _K 632.9D1160 Vol 50, _K 652.8 D1160 Vol 90, _K 697.7 TBP, _K 659.05 K factor11.38 Pentane Insoluble, % w 0.01 Ash Fe <1 Ni <1 V <1 MCRT, % w 0.01Crude Assay Results for 0.30*(SV) Test Stage 4 Temperature = 600 _F. IBPto 200 _C. 200 to 350 _C. 350 to 492_C. >492 _C. % weight 10.6 60.5 28.30.6 density 0.7828 0.8875 0.929 API gravity 49.09 27.78 20.67 S, % w1.16 1.88 2.78 N, mg/l 25.59 124.5 ppm 0.15 wt % C 84.92 85.12 84.87 H12.54 12.2 12.12 H/C 1.76 1.71 1.70 Mercaptans, % w Aromatics, % v 40.756.3 Olefins, % v 6.3 14.5 Saturates, % v 53.0 Aniline Point, _C. 52.355.2 Viscosity, 40 _C. 4.125 Viscosity, 50 _C. 3.34 19.524 Viscosity,100 _C. 4.476 D86 T10, _C. 247.4 D86 T50, _C. 286.2 D86 T80, _C. 306.8D86 T90, _C. 318.2 US Cetane 39.9 Canadian Cetane 37.6 Cloud Point, _C.−58 Freezing Point, _C. −47.3 Pour Point, _C. −60 −30 TAN, mg KOH/g 0.471.02 D1160 Vol 10, _K 650.45 D1160 Vol 50, _K 680.05 D1160 Vol 90, _K731.65 TBP, _K 685.5 K factor 11.55 Pentane Insoluble, % w 0.00 Ash Fe<1 Ni <1 V <1 MCRT, % w 0.01 Crude Assay Results for 0.36*(SV) TestStage 4 Temperature = 631 _F. IBP to 200 _C. 200 to 350 _C. 350 to 500_C. >500 _C. % weight 12.1 50.8 36.3 0.8 density 0.7844 0.8859 0.9297API gravity 48.72 28.07 20.55 S, % w 1.49 2.07 3.05 N, mg/l 26.5 124.20.14 wt % C 84.48 85.05 84.88 H 14.16 12.78 12.13 H/C 2.00 1.79 1.70Mercaptans, % w Aromatics, % v 16.5 36.7 Olefins, % v 12.7 6.9Saturates, % v 70.8 56.4 Aniline Point, _C. 50.7 53.6 Viscosity, 40 _C.3.878 Viscosity, 50 _C. 3.127 17.968 Viscosity, 100 _C. 4.141 D86 T10,_C. 243.5 D86 T50, _C. 281.4 D86 T80, _C. 302.2 D86 T90, _C. 314.4 USCetane 39.5 Canadian Cetane 36.8 Cloud Point, _C. −49 Freezing Point,_C. −45.5 Pour Point, _C. −57 −27 TAN, mg KOH/g 0.367 0.653 D1160 Vol10, _K 623.5 D1160 Vol 50, _K 650.6 D1160 Vol 90, _K 702.6 TBP, _K 656.8K factor 11.37 Pentane Insoluble, % w 0.0 Ash Fe <1 Ni <1 V <1 MCRT, % w0.01 Crude Assay Results for 0.42*(SV) Test Stage 4 Temperature = 600_F. IBP to 200 _C. 200 to 350 _C. 350 to 488 _C. >488 _C. % weight 12.761.5 25.2 0.6 density 0.7772 0.8847 0.9289 API gravity 50.39 28.29 20.68S, % w 1.05 1.84 2.80 N, mg/l 21.21 104.3 0.16 wt % C 85.2 85.0 84.86 H14.22 13.01 11.96 H/C 1.99 1.82 1.68 Mercaptans, % w Aromatics, % v 15.141.8 Olefins, % v 11.0 7.9 Saturates, % v 73.9 50.3 Aniline Point, _C.52.7 54.3 Viscosity, 40 _C. 4.008 Viscosity, 50 _C. 3.189 19.161Viscosity, 100 _C. 4.395 D86 T10, _C. 243.3 D86 T50, _C. 282.8 D86 T80,_C. 306.3 D86 T90, _C. 316.2 US Cetane 40.1 Canadian Cetane 37.9 CloudPoint, _C. −51 Freezing Point, _C. −46.5 Pour Point, _C. −57 −24 TAN, mgKOH/g 0.452 0.864 D1160 Vol 10, _K 633.8 D1160 Vol 50, _K 653.3 D1160Vol 90, _K 700.7 TBP, _K 660.3 K factor 11.40 Pentane Insoluble, % w 0.0Ash Fe <1 Ni <1 V <1 MCRT, % w 0.01 Crude Assay Results for 0.48*(SV)Test Stage 4 Temperature = 630 _F. IBP to 200 _C. 200 to 350 _C. 350 to474 _C. >474 _C. % weight 15.7 61.6 22.1 0.6 density 0.7724 0.88290.9266 API gravity 51.52 28.61 21.06 S, % w 0.9248 1.7218 2.67 N, mg/l16.63 82.20 0.13 wt % C 85.14 85.09 84.99 H 13.97 13.09 12.30 H/C 1.961.83 1.72 Mercaptans, % w Aromatics, % v 18.0 39.3 Olefins, % v 17.2 6.7Saturates, % v 64.8 54.0 Aniline Point, _C. 53.3 58.7 Viscosity, 40 _C.3.917 Viscosity, 50 _C. 3.102 18.02 Viscosity, 100 _C. 4.215 D86 T10,_C. 241.1 D86 T50, _C. 280.3 D86 T80, _C. 304.5 D86 T90, _C. 315.7 USCetane 40.1 Canadian Cetane 38.3 Cloud Point, _C. −52 Freezing Point,_C. −46.5 Pour Point, _C. −57 −30 TAN, mg KOH/g 0.484 D1160 Vol 10, _K627.3 D1160 Vol 50, _K 651.3 D1160 Vol 90, _K 698.5 TBP, _K 657.1 Kfactor 11.41 Pentane Insoluble, % w 0.0 Ash Fe <1 Ni <1 V <1 MCRT, % w0.1

1. A hydrocarbonaceous material processing apparatus, comprising: acontinuous input element through which a liquid hydrocarbonaceousmaterial is continuously input at an input rate; a first thermalenvironment having a volumetric capacity and in which at least a firstportion of said hydrocarbonaceous material is held at a firsttemperature and for a first residence time; a heat source established toheat the hydrocarbonaceous material held in said first thermalenvironment to said first temperature for at least a non-negligibleportion of said residence time, thereby thermally soaking thehydrocarbonaceous material held in said first thermal environment atsaid first temperature; a vapor and gas collection system adapted tocollect gas and vapor yielded during said thermal soak; a condenserestablished to condense said vapor; and a continuous output elementthrough which a liquid hydrocarbonaceous bottoms from said first thermalenvironment is continuously output at an output rate, wherein said firsttemperature is at least a hydrocarbonaceous material constituent boilingpoint temperature, and wherein said input rate, said output rate, andsaid volumetric capacity are coordinated so that said residence time issufficient to crack some of said hydrocarbonaceous material in saidfirst thermal environment during said thermal soak, thereby producingthrough chemical reaction and vaporization, a vaporizedhydrocarbonaceous material having a condensation point temperature thatis less than or equal to said hydrocarbonaceous material constituentboiling point temperature.
 2. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said at least a first portionof said hydrocarbonaceous material is held without physical agitation.3. A hydrocarbonaceous material processing apparatus as described inclaim 1 further comprising the step of not substantially exceeding saidhydrocarbonaceous material constituent boiling point temperature duringsaid residence time.
 4. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said first temperature isgreater than 550° F.
 5. A hydrocarbonaceous material processingapparatus as described in claim 1 further comprising a second thermalenvironment having a second volumetric capacity and in which at least asecond portion of said hydrocarbonaceous material is held at a secondtemperature for a second residence time.
 6. A hydrocarbonaceous materialprocessing apparatus as described in claim 5 wherein said secondvolumetric capacity is different from said first volumetric capacity. 7.A hydrocarbonaceous material processing apparatus as described in claim5 wherein said second temperature is greater than said firsttemperature.
 8. A hydrocarbonaceous material processing apparatus asdescribed in claim 5 wherein said second thermal environment isestablished downstream of said first thermal environment.
 9. Ahydrocarbonaceous material processing apparatus as described in claim 5wherein said first thermal environment is established by a first vesseland said second thermal environment is established by a second vesselthat is different from said first vessel.
 10. A hydrocarbonaceousmaterial processing apparatus as described in claim 5 wherein said firstand said second thermal environments are each partially established bythe same vessel and segregated by a wier within said vessel.
 11. Ahydrocarbonaceous material processing apparatus as described in claim 5further comprising a third thermal environment having a third volumetriccapacity and in which at least a third portion of said hydrocarbonaceousmaterial is held for a third residence time.
 12. A hydrocarbonaceousmaterial processing apparatus as described in claim 11 wherein saidthird temperature is greater than said second first temperature and saidsecond temperature.
 13. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said hydrocarbonaceousmaterial constituent boiling point temperature is above a liquid waterboiling point temperature.
 14. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said hydrocarbonaceousmaterial constituent boiling point temperature is substantially at aliquid water boiling point temperature.
 15. A hydrocarbonaceous materialprocessing apparatus as described in claim 1 wherein saidhydrocarbonaceous material constituent boiling point temperature is lessthan a coking temperature.
 16. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said hydrocarbonaceousmaterial constituent boiling point temperature is a low boiling pointtemperature.
 17. A hydrocarbonaceous material processing apparatus asdescribed in claim 16 wherein low is selected from the group consistingof: less than 40° F., less than 70° F., less than 100° F., less than150° F., less than 200° F., less than 250° F., less than 300° F., lessthan 370° F., less than 400° F., less than 450° F., less than 500° F.,less than 550° F., less than 600° F., less than 650° F., less than 700°F., and less than 710° F.
 18. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said cracking is mildcracking.
 19. A hydrocarbonaceous material processing apparatus asdescribed in claim 18 wherein a bromine number of the naptha fraction ofcondensed vapor is 20 or less.
 20. A hydrocarbonaceous materialprocessing apparatus as described in claim 1 further comprising acondenser established to condense said vapor that is removed by said gasand vapor collection system.
 21. A hydrocarbonaceous material processingapparatus as described in claim 20 wherein said condenser is separatefrom said first thermal environment.
 22. A hydrocarbonaceous materialprocessing apparatus as described in claim 20 wherein said condenser isintegrated within said first thermal environment.
 23. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said first thermal environment is a vessel.
 24. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said first residence time is at least one hour.
 25. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said first residence time is less than eight hours.
 26. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said input rate and said output rate are each is continuousduring operation of said apparatus.
 27. A hydrocarbonaceous materialprocessing apparatus as described in claim 1 wherein said input rate isequal to said output rate.
 28. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said first residence time andsaid first temperature can be adjusted to yield vapors as desired.
 29. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said temperature, said volumetric capacity said input rate, andsaid output rate can be adjusted to vary residence time.
 30. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said liquid hydrocarbonaceous material input at said input rateis substantially non-pumpable.
 31. A hydrocarbonaceous materialprocessing apparatus as described in claim 30 wherein said liquidhydrocarbonaceous material input at said input rate is bitumen.
 32. Ahydrocarbonaceous material processing apparatus as described in claim 30wherein said hydrocarbonaceous material input at said input rate isextra heavy oil.
 33. A hydrocarbonaceous material processing apparatusas described in claim 1 wherein said gas and vapor collection systemcomprises a sweep gas system.
 34. A hydrocarbonaceous materialprocessing apparatus as described in claim 33 wherein said sweep gas isgas collected by said gas and vapor removal apparatus
 35. Ahydrocarbonaceous material processing apparatus as described in claim 33wherein said sweep gas comprises methane
 36. A hydrocarbonaceousmaterial processing apparatus as described in claim 1 wherein saidliquid hydrocarbonaceous bottoms are output for further processing by acoker.
 37. A hydrocarbonaceous material processing apparatus asdescribed in claim 36 wherein said coker comprises a continuous coker.38. A hydrocarbonaceous material processing apparatus as described inclaim 1 wherein said thermal environment is heated at slightly aboveatmospheric pressure.
 39. A hydrocarbonaceous material processingapparatus as described in claim 1 wherein said crack is moderate.
 40. Ahydrocarbonaceous material processing apparatus as described in claim 1wherein said low boiling point temperature is selected so as to remove alow boiling point hydrocarbonaceous material constituent of interest.41. A hydrocarbonaceous material processing apparatus as described inclaim 1 wherein said apparatus is usable in a pumpable oil preparationsystem.
 42. A hydrocarbonaceous material processing apparatus asdescribed in claim 1 wherein said apparatus is usable whenever need toremove low boiling point materials.
 43. A hydrocarbonaceous materialprocessing apparatus as described in claim 42 wherein said apparatus isusable whenever there is a need to remove water.
 44. A hydrocarbonaceousmaterial processing apparatus as described in claim 1 wherein saidliquid hydrocarbonaceous material passing through said continuous inputis input is anhydrous.
 45. A hydrocarbonaceous material processingapparatus as described in claim 44 wherein said water removed viasettling tank.
 46. A hydrocarbonaceous material processing apparatus asdescribed in claim 44 wherein said water removed via free expansion. 47.A hydrocarbonaceous material processing apparatus, comprising: acontinuous input element through which a liquid hydrocarbonaceousmaterial is continuously input at an input rate; a thermal environmenthaving a volumetric capacity and in which at least a first portion ofsaid liquid hydrocarbonaceous material is held for a residence time andwithout physical agitation; a heat source established to heat thehydrocarbonaceous material held in said thermal environment to a firsttemperature for said residence time, thereby thermally soaking thehydrocarbonaceous material held in said thermal environment at saidfirst temperature; a vapor and gas collection system established tocollect gas and vapor yielded during said thermal soak; a condenserestablished to condense said vapor; and a continuous output elementthrough which at least a portion of said hydrocarbonaceous bottoms fromsaid thermal environment is continuously output at an output rate to acontinuous coker, wherein said first temperature is at least ahydrocarbonaceous material constituent boiling point temperature, andwherein said continuous input rate, said continuous output rate, andsaid volumetric capacity are coordinated so that said residence time issufficient to crack some of said hydrocarbonaceous material in saidthermal environment during said thermal soak, thereby producing throughchemical reaction and vaporization, a vaporized hydrocarbonaceousmaterial having a condensation point temperature that is less than orequal to said hydrocarbonaceous material constituent boiling pointtemperature.
 48. A hydrocarbonaceous material processing apparatus asdescribed in claim 47 further comprising a second thermal environment towhich said hydrocarbonaceous bottoms is continuously input, wherein saidsecond thermal environment is characterized by a second temperature thatis greater than said first temperature.
 49. A hydrocarbonaceous materialprocessing apparatus as described in claim 48 wherein said firsttemperature is substantially a liquid water boiling temperature.
 50. Ahydrocarbonaceous material processing apparatus as described in claim 47wherein said apparatus is established at an oil extraction site.
 51. Ahydrocarbonaceous material processing apparatus as described in claim 47wherein said liquid hydrocarbonaceous material input to said firstthermal environment is substantially non-pumpable oil.
 52. Ahydrocarbonaceous material processing apparatus as described in claim 47wherein said first temperature is less than a coke formationtemperature.
 53. A hydrocarbonaceous material processing methodcomprising the steps of: inputting a hydrocarbonaceous material to afirst thermal environment; holding said hydrocarbonaceous material insaid first thermal environment at a first temperature and for a firstnon-negligible residence time to yield hydrocarbonaceous vapors;outputting a first portion of said hydrocarbonaceous material; inputtingat least some of said first portion of said hydrocarbonaceous materialto a second thermal environment; holding said at least some of saidfirst portion of said hydrocarbonaceous material in said second thermalenvironment at a second temperature and for a second non-negligibleresidence time to yield hydrocarbonaceous vapors; outputting a secondportion of said hydrocarbonaceous material; and generating a condensedcombination of vapors yielded during said holding steps.
 54. Ahydrocarbonaceous material processing method as described in claim 53wherein said first thermal environment is established by a vessel.
 55. Ahydrocarbonaceous material processing method as described in claim 53wherein said second thermal environment is established by a vessel. 56.A hydrocarbonaceous material processing method as described in claim 53wherein said second temperature is higher than said first temperature.57. A hydrocarbonaceous material processing method as described in claim53 wherein said first non-negligible residence time is at least one hourbut not greater than eight hours.
 58. A hydrocarbonaceous materialprocessing method as described in claim 53 wherein said firstnon-negligible residence time is different from said secondnon-negligible residence time.
 59. A hydrocarbonaceous materialprocessing method as described in claim 53 further comprising said stepof coking at least some of said second portion of said hydrocarbonaceousmaterial.
 60. A hydrocarbonaceous material processing method asdescribed in claim 53 wherein said step of generating a condensedcombination of said vapors comprises the step of first combining saidvapors and then condensing said vapors.
 61. A hydrocarbonaceous materialprocessing method as described in claim 53 further comprising the stepof affirmatively assuring that a viscosity of said condensed combinationhas a viscosity that substantially matches a pumpable oil viscosityspecification.
 62. A hydrocarbonaceous material processing method asdescribed in claim 61 wherein said step of affirmatively assuringcomprises the step of coordinating temperatures and residence times suchthat said condensed combination of vapors has a viscosity thatsubstantially matches a pumpable oil viscosity specification.
 63. Ahydrocarbonaceous material processing method as described in claim 61wherein said step of affirmatively assuring comprises the step of addingat least a portion of said condensed combination of vapors to asubstantially non-pumpable hydrocarbonaceous material.
 64. Ahydrocarbonaceous material processing method as described in claim 63wherein said hydrocarbonaceous material input to said first thermalenvironment is a sidestream fraction of said substantially non-pumpablehydrocarbonaceous material.
 65. A hydrocarbonaceous material processingmethod as described in claim 53 wherein each of said steps of inputtingcomprises continuously inputting.
 66. A hydrocarbonaceous materialprocessing method as described in claim 53 wherein each of said steps ofoutputting comprises continuously outputting.
 67. A hydrocarbonaceousmaterial processing method as described in claim 53 wherein each of saidtemperatures is less than a coke formation temperature.
 68. Ahydrocarbonaceous material processing method comprising the steps of:continuously inputting a hydrocarbonaceous material to a first thermalenvironment; holding said hydrocarbonaceous material in a first thermalenvironment for a first non-negligible residence time and at a firsttemperature so as to thermally soak said hydrocarbonaceous material andyield hydrocarbonaceous material constituent vapors; and continuouslyoutputting a first portion of said hydrocarbonaceous material.
 69. Ahydrocarbonaceous material processing method as described in claim 68further comprising the step of continuously inputting at least some ofsaid first portion of said hydrocarbonaceous material to a coker.
 70. Ahydrocarbonaceous material processing method as described in claim 68further comprising the step of holding said first portion of saidhydrocarbonaceous material in a second thermal environment for a secondnon-negligible residence time and at a second temperature so as tothermally soak said first portion of said hydrocarbonaceous material.71. A hydrocarbonaceous material processing method as described in claim70 further comprising the step of continuously outputting a secondportion of said hydrocarbonaceous material.
 72. A hydrocarbonaceousmaterial processing method as described in claim 71 further comprisingthe step of holding said second portion of said hydrocarbonaceousmaterial in a third thermal environment for a third non-negligibleresidence time and at a third temperature so as to thermally soak saidsecond portion of said hydrocarbonaceous material.
 73. Ahydrocarbonaceous material processing method as described in claim 72repeating holding steps in different thermal environments until vaporsyielded during said holding step are minimal.
 74. A hydrocarbonaceousmaterial processing method as described in claim 68 wherein said methodis practiced in the field.
 75. A hydrocarbonaceous material processingmethod as described in claim 74 wherein said method is practicedsubstantially at an oil extraction site.
 76. A hydrocarbonaceousmaterial processing method as described in claim 74 wherein said methodis part of a process to produce a pumpable hydrocarbonaceous materialfrom a substantially non-pumpable hydrocarbonaceous material.
 77. Ahydrocarbonaceous material processing method comprising the steps of:continuously inputting a liquid hydrocarbonaceous material; holding atleast a portion of said liquid hydrocarbonaceous material in a firstthermal environment for a first non-negligible residence time and at afirst temperature so as to thermally soak said hydrocarbonaceousmaterial; yielding hydrocarbonaceous vapors and a first liquidhydrocarbonaceous bottoms; and continuously outputting said first liquidhydrocarbonaceous bottoms; continuously inputting at least a portion ofsaid first liquid hydrocarbonaceous bottoms; holding said at least aportion of said first liquid hydrocarbonaceous bottoms in a secondthermal environment for a second non-negligible residence time and at asecond temperature that is higher than said first temperature, so as tothermally soak said liquid hydrocarbonaceous bottoms; yieldingadditional hydrocarbonaceous vapors and a second liquidhydrocarbonaceous bottoms that is less massive than said first liquidhydrocarbonaceous bottoms; and outputting said second liquidhydrocarbonaceous bottoms; generating a condensed combination of saidhydrocarbonaceous vapors; affirmatively assuring that a viscosity of anoil for pipe transport of which said condensed combination forms atleast a part has a viscosity that substantially matches a pumpable oilviscosity specification.
 78. A hydrocarbonaceous material processingmethod as described in claim 77 further comprising the steps of:continuously inputting at least a portion of said second liquidhydrocarbonaceous bottoms; holding said at least a portion of saidliquid hydrocarbonaceous bottoms in a third thermal environment for athird non-negligible residence time and at a third temperature that ishigher than said second temperature, so as to thermally soak said liquidhydrocarbonaceous bottoms; yielding additional hydrocarbonaceous vaporsand a third liquid hydrocarbonaceous bottoms that is less massive thansaid first liquid hydrocarbonaceous bottoms; and outputting said thirdliquid hydrocarbonaceous bottoms.
 79. A hydrocarbonaceous materialprocessing method as described in claim 77 further comprising the stepof coking at least a portion of said second liquid hydrocarbonaceousbottoms.
 80. A hydrocarbonaceous material processing method as describedin claim 77 wherein said step of affirmatively assuring comprises thestep of coordinating temperatures and residence times so that saidviscosity substantially matches said pumpable oil viscosityspecification.
 81. A hydrocarbonaceous material processing method asdescribed in claim 77 wherein said step of affirmatively matchingcomprises the step of adding said condensed combination of saidhydrocarbonaceous vapors to a substantially non-pumpable oil to generatesaid oil for pipe transport.
 82. A hydrocarbonaceous material processingmethod as described in claim 81 wherein liquid hydrocarbonaceousmaterial continuously input into said first thermal environment is asidestream fraction of said substantially non-pumpable oil.
 83. Ahydrocarbonaceous material viscosity reduction method comprising thesteps of: heating a first substantially unpumpable crude oil having afirst viscosity to at least a first hydrocarbonaceous materialconstituent boiling point temperature; vaporizing at least some of saidsubstantially unpumpable crude oil to produce a first mass ofhydrocarbonaceous material vapor; producing, through chemical reaction,a second mass of hydrocarbonaceous material vapor whose condensationpoint temperature is equal to or less than said hydrocarbonaceousmaterial constituent boiling temperature; generating a first liquidhydrocarbonaceous material bottoms forming a hydrocarbonaceous materialcondensate from at least said first and second mass of hydrocarbonaceousmaterial vapors wherein said hydrocarbonaceous material condensate has asecond viscosity that is less than said first viscosity; affirmativelyassuring said hydrocarbonaceous material condensate has a viscosity thatsubstantially matches an oil pumping viscosity specification.
 84. Ahydrocarbonaceous material viscosity reduction method as described inclaim 83 further comprising the steps of: heating said liquidhydrocarbonaceous material bottoms to at least a secondhydrocarbonaceous material constituent boiling point temperature that ishigher than said first hydrocarbonaceous material constituent boilingpoint temperature; vaporizing at least some of said liquidhydrocarbonaceous material bottoms to produce a third mass ofhydrocarbonaceous material vapor; producing, through chemical reaction,a fourth mass of hydrocarbonaceous material vapor whose condensationpoint temperature is equal to or less than said second hydrocarbonaceousmaterial constituent boiling temperature; generating a second liquidhydrocarbonaceous material bottoms.
 85. A hydrocarbonaceous materialviscosity reduction method as described in claim 84 wherein said step offorming a hydrocarbonaceous material condensate from at least said firstand second mass of hydrocarbonaceous material vapors comprises the stepof forming a hydrocarbonaceous material condensate from at least saidfirst, second, third and fourth mass of hydrocarbonaceous vapors.
 86. Ahydrocarbonaceous material viscosity reduction method as described inclaim 83 further comprising the steps of serially repeating the group ofsaid steps of heating, vaporizing, producing and generating, where eachsubsequently performed group of said steps acts on a liquid bottomsgenerated by an immediately prior group of said steps.
 87. Ahydrocarbonaceous material viscosity reduction method as described inclaim 86 wherein said group of said steps is repeated until it costsmore to conduct said repeated group of said steps than is the economicvalue of the yield of said repeated group of said steps.
 88. Ahydrocarbonaceous material viscosity reduction method as described inclaim 83 wherein affirmatively assuring comprises the step of addingsaid hydrocarbonaceous material condensate to a second substantiallyunpumpable crude oil amount so as to produce a hydrocarbonaceousmaterial whose viscosity substantially matches an oil pumping viscosityspecification.
 89. A hydrocarbonaceous material viscosity reductionmethod as described in claim 83 wherein affirmatively assuring comprisesthe step of selecting method parameters that result in ahydrocarbonaceous material condensate whose viscosity substantiallymatches an oil pumping viscosity specification.
 90. A hydrocarbonaceousmaterial viscosity reduction method as described in claim 83 whereinsaid substantially unpumpable crude oil comprises extra heavy oil.
 91. Ahydrocarbonaceous material viscosity reduction method as described inclaim 83 wherein said substantially unpumpable crude oil comprisesbitumen.
 92. A hydrocarbonaceous material viscosity reduction method asdescribed in claim 83 wherein said step of producing a second mass ofhydrocarbonaceous material vapor comprises the step of holding a firstsubstantially unpumpable crude oil for a residence time.
 93. Ahydrocarbonaceous material viscosity reduction method as described inclaim 83 further comprising the step of coking at least a portion ofsaid first liquid hydrocarbonaceous material bottoms.
 94. Ahydrocarbonaceous material processing apparatus, comprising: at leasttwo thermal environments established in series, each said thermalenvironment adapted to: accept at least a portion of a hydrocarbonaceousmaterial thereafter heat said at least a portion of a hydrocarbonaceousmaterial for a residence time to generate hydrocarbonaceous vaporsthrough chemical reaction and vaporization; and thereby generate aliquid hydrocabonaceous material bottoms, wherein said at least twothermal environments are further established such that each thermalenvironment is either upstream or downstream of a different thermalenvironment; wherein said at least a portion of a hydrocarbonaceousmaterial accepted by a downstream thermal environment is the liquidhydrocarbonaceous material bottoms generated by an upstream thermalenvironment, wherein a temperature to which said at least a portion of ahydrocarbonaceous material is heated in a downstream thermal environmentis higher than that temperature to which said at least a portion of ahydrocarbonaceous material is heated in an upstream thermal environment,and further comprising: a condensate generation apparatus that generatesa condensate from said hydrocarbonaceous vapors.
 95. A hydrocarbonaceousmaterial processing apparatus as described in claim 94 wherein said atleast two thermal environments comprises at least three thermalenvironments.
 96. A hydrocarbonaceous material processing apparatus asdescribed in claim 94 wherein said at least three thermal environmentscomprises at least four thermal environments.
 97. A hydrocarbonaceousmaterial processing apparatus as described in claim 96 wherein said atleast four thermal environments comprises at least six thermalenvironments.
 98. A hydrocarbonaceous material processing apparatus asdescribed in claim 94 wherein said at least two thermal environmentscomprises that number of thermal environments that yields vapors that,when condensed, result in a desired processing economics.
 99. Ahydrocarbonaceous material processing apparatus as described in claim 94wherein said at least two thermal environments comprises that number ofthermal environments that yields vapors that, upon being condensed, havea viscosity that is less than or equal to a pumpable oil viscosityspecification
 100. A hydrocarbonaceous material processing apparatus asdescribed in claim 94 wherein said at least two thermal environments areeach adapted to continuously accept said at least a portion of ahydrocarbonaceous material and continuously generate a liquidhydrocarbonaceous material bottoms.
 101. A hydrocarbonaceous materialprocessing apparatus as described in claim 94 further comprising acondensate admixing apparatus that dilutes a substantially unpumpableoil to a viscosity specification.
 102. A hydrocarbonaceous materialprocessing apparatus as described in claim 94 further comprises asidestream fraction withdrawal systems withdrawal the hydrocarbonaceousmaterial accepted by the thermal environment that is furthest upstreamfrom a crude oil flow.
 103. At least two thermal environmentsestablished in series as described in claim 94 wherein said condensategeneration apparatus comprises a sweep gas system.
 104. At least twothermal environments established in series as described in claim 103wherein said sweep gas is recycled methane.
 105. At least two thermalenvironments established in series as described in claim 94 wherein thehydrocarbonaceous material accepted by the furthest upstream thermalenvironment is a substantially non-pumpable hydrocarbonaceous material.106. A hydrocarbonaceous material processing apparatus as described inclaim 105 wherein said substantially non-pumpable hydrocarbonaceousmaterial comprises bitumen.
 107. A hydrocarbonaceous material processingapparatus as described in claim 105 wherein said substantiallynon-pumpable hydrocarbonaceous material comprises extra heavy oil. 108.A hydrocarbonaceous material processing apparatus as described in claim94 wherein said condensate has a viscosity that is at most a pumpableoil viscosity specification.
 109. A hydrocarbonaceous materialprocessing apparatus as described in claim 94 further comprises a cokerthat accepts a liquid hydrocarbonaceous bottoms generated by animmediately upstream thermal environment.
 110. A hydrocarbonaceousmaterial processing apparatus as described in claim 109 wherein saidcoker generates coke, non-condensible gas and condensable vapor.
 111. Ahydrocarbonaceous material processing apparatus as described in claim110 further comprises a non-condensible gas collector that delivers gasgenerated by said coker for use as a heat source for the coker or atleast one thermal environment.
 112. A hydrocarbonaceous materialprocessing apparatus as described in claim 110 wherein said condensategeneration apparatus generates condensate that comprises condensed vaporgenerated by said coker.
 113. A hydrocarbonaceous material processingapparatus as described in claim 110 further comprises a hydrotreatingapparatus that hydrotreats vapor generated by said coker, and whereinsaid hydrotreater yields liquid.
 114. A hydrocarbonaceous materialprocessing apparatus as described in claim 113 further comprising anadmixer that adds said liquid yielded by said hydrotreater to saidcondensate.
 115. A hydrocarbonaceous material processing apparatus asdescribed in claim 113 further comprises a spent hydrogen recycler thatrecycles hydrogen yielded by hydrotreating process for use in subsequenthydrotreating.
 116. A hydrocarbonaceous material processing apparatus asdescribed in claim 115 further comprises a cleanser that removeshydrogen sulfide before recycling said hydrogen.
 117. An apparatus forreducing the viscosity of hydrocarbons, comprising: a plurality of oilprocessing stages in series, each stage itself comprising an inputelement through which a liquid hydrocarbon is input at predeterminedrate; a thermal environment having a known volumetric capacity and inwhich said liquid hydrocarbon is held for a known and finite residencetime; a heat source established to heat said liquid hydrocarbon held insaid thermal environment to a set temperature for said residence time,thereby thermally soaking said liquid hydrocarbon; a vapor and gascollection system to collect gases and vapors yielded during saidthermal soak; a condenser established to condense said vapors producedduring said thermal soak; and an output element through whichhydrocarbon bottoms from said thermal environment are output, whereinsaid input rate, said output rate, and said volumetric capacity arecoordinated so that said residence time is sufficient to producehydrocarbonaceous materials through chemical reaction and vaporization.118. An apparatus for reducing the viscosity of hydrocarbons asdescribed in claim 117 wherein each successive stage comprises a thermalenvironment in which a hydrocarbon is heated to a higher temperaturethan prior stages.
 119. A viscosity reduction method for liquidhydrocarbons comprising the steps of: heating a hydrocarbon having afirst viscosity to a series of predetermined soak temperatures for aseries of predetermined soak times; vaporizing at least some of saidhydrocarbon to produce a first mass of hydrocarbon vapors; producing,through chemical reaction, a second mass of hydrocarbon vapors whoseboiling points are equal to or less than the boiling points of theoriginal hydrocarbon; removing hydrocarbon bottoms from unvaporizedmaterials condensing the first and second masses of hydrocarbon vaporsto form a hydrocarbon condensate where said hydrocarbon condensate has asecond viscosity that is less than said first viscosity.